Disposable scrubbing product

ABSTRACT

The present invention discloses a disposable scrubbing product for use in household cleaning or personal care applications. In one embodiment, the present invention is directed to a cleaning tool including a handle and a rigid base to which the scrubbing product of the present invention may be attached to form a convenient cleaning tool. The scrubbing product of the invention is a multi-layer laminate product and generally includes at least two distinct layers, an abrasive layer and an absorbent fibrous layer such as a layer tissue made from papermaking fibers, a layer of coform, an airlaid web, or combinations thereof. The abrasive layer is formed primarily of polymeric fibers in a disordered or random distribution as is typical of fibers deposited in meltblown or spunbond processes so as to form an open, porous structure. In one embodiment, the abrasive layer comprises multifilamentary aggregate fibers. In one embodiment, the absorbent fibrous layer is an uncreped, through dried paper web.

BACKGROUND OF THE INVENTION

[0001] Abrasive scrubbing pads are commonly used for many cleaning andpersonal care practices. In general, scrubbing pads include a naturallyoccurring or manufactured abrasive material. Examples of typicalabrasive materials commonly used in the past include pumice, loofah,steel wool, and a wide variety of plastic materials. A non-absorbentabrasive material is often combined with an absorbent sponge-likebacking material in these products. For example, the abrasive materialoften forms a layer on a multi-layer product which also includes anabsorbent layer of natural sponge, regenerated cellulose, or some othertype of absorbent foamed product.

[0002] These scrubbing pads tend to be expensive, making them unsuitablefor a disposable or single-use product. Due to the nature of the productuse, however, the products can become fouled with dirt, grease,bacteria, and other contaminants after only one or two uses. As aresult, consumers must replace these expensive scrubbing pads quiteoften in order to feel secure in the knowledge that they are using anuncontaminated cleaning pad.

[0003] Examples of abrasive cleaning articles have been described in thepast. See, for example, International Published Application Number WO02/41748, U.S. Pat. Nos. 5,213,588, and 6,013,349.

[0004] The present invention addresses these and other problemsencountered with scrubbing pads in the past and is directed todisposable scrubbing pads which can provide a wide variety in level ofabrasiveness, may be thin, comfortable and easy to hold, may have goodabsorbency, and may provide benefits not previously supplied in abrasivecleaning articles of the past.

SUMMARY OF THE INVENTION

[0005] The present invention is directed to a disposable scrubbingproduct for use in household cleaning or personal care applications, aswell as industrial cleaning and other applications. In one embodiment,the present invention is directed to a cleaning tool including a handleand a rigid base to which the scrubbing product of the present inventionmay be removably attached to form a convenient cleaning tool.

[0006] The scrubbing product of the invention is a multi-layer productand generally includes at least two distinct layers, an abrasive layerand an absorbent fibrous layer such as a layer of tissue made frompapermaking fibers, a layer of coform, an airlaid web, or combinationsthereof or other known cellulosic webs. The abrasive layer is formedprimarily of coarse polymeric fibers in a disordered or randomdistribution as is typical of fibers deposited in meltblown or spunbondprocesses. In one embodiment, the abrasive layer comprisesmultifilamentary aggregate fibers formed by the partial coalescence of aplurality of polymer strands (i.e. the individual fibers produced by theprocess) during a meltblown process or other fiber-forming process toform an integral, fiber-like, generally non-circular structure in whichsubstantially parallel polymeric filaments are joined along their sides.Such multifilamentary aggregates may have an effective diameter muchgreater than the individual strands normally obtained in meltblown orspunbond processes, and a complex cross-sectional shape more suitablefor providing abrasion than can be achieved with conventional circularfibers, and can contribute to effective cleaning and abrasion.

[0007] The polymeric fibers in the abrasive layer generally form anopen, porous structure. For instance, the open void space within theabrasive layer may be greater than about 10%, particularly greater thanabout 50% more particularly greater than about 60% of the total volumeof the abrasive layer. Further, a significant percentage of thesuperficial surface area of the abrasive layer (that is, the total areadefined by the surface of the abrasive layer) may be occupied byopenings through which the underlying absorbent layer can be seen. Forexample, about 10% or greater, specifically about 20% or greater, morespecifically about 40% or greater, and most specifically about 55% orgreater of the superficial surface area of the abrasive layer (the areaseen in plan view from above) may be occupied by openings through whichthe underlying absorbent layer can be seen. The absorbent layer of thescrubbing product may include a paper web, for instance, the absorbentlayer may include an uncreped, throughdried paper web.

[0008] The abrasive layer may be formed of polymeric materials, such assynthetic thermoplastic polymers suitable for fiber formation in ameltblown or spunbond process. Thermosetting polymers may also be used,as well as photocurable polymers and other curable polymers. In oneembodiment, the fibers may be formed of thermoplastic polymers such aspolyolefins, polyesters, polyetheresters, nylons, polyamides, or anysuitable copolymers. In one particular embodiment, the abrasive fibersmay be formed of a polypropylene. Optionally, the fibers may bebicomponent or multi-component fibers. If desired, the abrasive layermay be formed of two or more different types of abrasive fibers. Forexample, the abrasive layer may include different fiber types mixedtogether heterogeneously throughout the layer. Alternatively, theabrasive layer may include different fiber types laid down in a morehomogeneous fashion, such as in sublayers across the cross section ofthe abrasive layer. In one embodiment, the polymeric fibers of theabrasive layer are substantially free of plasticizers, or may have 33weight percent plasticizer or less, more specifically about 20 weightpercent plasticizer or less, more specifically still about 10 weightpercent plasticizer or less, and most specifically about 3 weightpercent plasticizer or less. The dominant polymer in the polymericfibers may have a molecular weight of any of the following: about100,000 or greater, about 500,000 or greater, about 1,000,000 orgreater, about 3,000,000 or greater, and about 5,000,000 or greater

[0009] In general, thermoplastic polymer fibers in the abrasive layermay be greater than about 30 microns in mean diameter. Morespecifically, thermoplastic fibers may be between about 40 microns andabout 800 microns in mean diameter, such as from about 40 microns to 600microns, more specifically from about 50 microns to 400 microns, morespecifically still from about 60 microns to 300 microns, and mostspecifically from about 70 microns to about 250 microns. Such fibers aresubstantially coarser than the fibers of conventional meltblown webs,and the added coarseness is generally helpful in increasing the abrasivecharacteristics of the web. The values of the mean fiber diameterspreviously specified may also refer to the width of non-circularmultifilamentary aggregates, described more fully hereafter. Forexample, a multifilamentary aggregates of two or more polymer strandsfused along their sides may have a width nearly two or more times thatof the individual unfused strands, such as a width of about 50 micronsto about 800 microns, or any other previously specified range. Inaddition, other widths may be achieved with multifilamentary aggregates,such as widths of about 100 microns of greater, about 250 microns orgreater, about 400 microns or greater, about 600 microns or greater, andabout 800 microns or greater.

[0010] The polymeric fibers in the abrasive layer may also be longerthan about 1 cm, specifically longer than about 2 cm, in the abrasivelayer of the scrubbing pad.

[0011] Other factors may contribute to the abrasive characteristics ofthe abrasive layer. In addition to being coarse, the fibers of theabrasive layer may have a high elastic modulus, such as an elasticmodulus roughly equal to or greater than that of polypropylene such asabout 1000 MPa or greater, specifically about 2000 MPa or greater, morespecifically about 3000 MPa or greater, and most specifically about 5000MPa or greater. By way of example, phenol plastics may have elasticmoduli of about 8000 MPa, and a polyamide (nylon 6,6) reinforced with15% glass fiber has a reported elastic modulus of 4,400 MPa (whereas theelastic modulus is about 1,800 MPa without the glass reinforcement).

[0012] For some polymer groups, an increased melting point may correlatewith improved abrasive features. Thus, in one embodiment, the abrasivefibers may have a melting point greater than 120° C., such as about 140°C. or greater, about 160° C. or greater, about 170° C. or greater, about180° C. or greater, or about 200° C. or greater, exemplified by thefollowing ranges: from about 120° C. to about 350° C., from about 150°C. to about 250° C., or from about 160° C to about 210° C.

[0013] In some embodiments, polymers with relatively high viscosity orlow melt flow rates may be useful in producing coarse webs for effectivecleaning. The melt flow rate of the polymer is measured according toASTM D1238. While polymers typically used in meltblowing operations mayhave melt flow rates of about 1000 g/10 min or greater and may beconsidered in some embodiments of the present invention, in someembodiments the polymers used to produce an abrasive layer may have amelt flow rate according to ASTM D1238 less than 3000 g/10 min or 2000g/10 min, such as less than about 1000 g/10 min or less than about 500g/10 min, specifically less than 200 g/10 min, more specifically lessthan 100 g/10 min, and most specifically less than 80 g/10 min, such asfrom about 15 g/10 min to about 250 g/10 min, or from about 20 g/10 minto about 400 g/10 min.

[0014] The abrasiveness of the abrasive layer may further be enhanced bythe topography of the abrasive layer. For example, the abrasive layermay have a plurality of elevated and depressed regions due to nonuniformbasis weight, nonuniform thickness, or due to the three-dimensionaltopography of an underlying fibrous web such as a textured wetlaidtissue web. The elevated and depressed regions may be spaced apartsubstantially periodically in at least one direction such as the machinedirection or the cross direction with a characteristic wavelength ofabout 2 mm or greater, more specifically about 4 mm or greater, andhaving a characteristic height difference between the elevated anddepressed regions of at least 0.3 mm or greater, more specifically about0.6 mm or greater, more specifically still about 1 mm or greater, andmost specifically about 1.2 mm or greater.

[0015] In one embodiment, the abrasive layer consists essentially ofmeltblown or spunbond polymeric fibers and optional adhesive or otherbonding means. In another embodiment, the abrasive layer is not a scrimor does not comprise scrim. In a related embodiment, the abrasive layeris substantially free of ordered rectilinearly arranged fibers orpolymeric rubs on the surface (such as a scrim with extruded or moldedpolymeric rubs in an orderly pattern with one or more sets of parallelribs extending at least 3 cm or longer).

[0016] In some embodiments, the abrasive layer may formed directly on atissue layer, or may first be formed and then joined to the tissue byadhesive means, thermal bonding, and the like. When the abrasive layeris formed first, it may be provided with a three-dimensional topographyby formation on or molding on a suitable three-dimensional surface. Forexample, a meltblown web may be formed on a coarse carrier wire. If themeltblown fibers are still molten or partially molten when they impingeupon the wire, the texture of the wire may be imparted to the web,particularly with the assistance of hydraulic pressure across the wireto further press the meltblown fibers against the wire before they havefully solidified. Improved molding of meltblown fibers against a wiremay be achieved by using a suitably high temperature of the polymer orof the temperature of the air jets, and/or by adjusting the distancebetween the meltblown die and the carrier wire. The carrier wire mayhave a repeating series of depressions which may correspond to elevatedregions on the meltblown web useful for cleaning. A three-dimensionalcarrier wire may impart elevated structures to the meltblown that riseabout 0.2 mm or greater from the surrounding meltblown fabric, morespecifically about 0.4 mm or greater, depending upon the desired levelof abrasiveness. A spectrum of scrubby pads from mildly abrasive toaggressively abrasive may be produced.

[0017] The repeating structures may be represented as the minimumcharacteristic unit cell of the carrier wire, and the unit cell may havea minimum in-plane length scale (e.g., for a unit cell that is aparallelogram, the length of the shorter side, or for more complexshapes such as a hexagon, smaller of the machine direction width andcross-direction width) of about 1 mm or greater, such as about 2 mm orgreater, or may have an area of about 5 square millimeters or greater(e.g., a unit cell of dimensions 1 mm by 5 mm), or about 20 squaremillimeters or greater. A carrier wire may be treated with a releaseagent such as a silicone liquid or coated with Teflon® or other releaseagents to enhance removal of the textured meltblown web from the carrierwire.

[0018] The abrasive layer of the scrubbing pad may usually be greaterthan about 10 grams per square meter (gsm) in basis weight. Morespecifically, the abrasive layer may be between about 25 and about 200gsm in basis weight, more specifically still between about 30 and 150gsm, and most specifically between about 40 gsm and 130 gsm. Theabrasive layer may be joined to the underlying fibrous web directly dueto thermal bonding or other interactions of the abrasive material withthe fibrous web (e.g., hydroentangling, needling, etc.), wherein thereis substantially no added adhesive joining the fibers of the abrasivelayer to the absorbent fibrous web. In another embodiment, hot melt orcured adhesive is applied joining the two layers, wherein the basisweight of the adhesive is about 5 gsm or greater, such as from about 10gsm to about 50 gsm, more specifically from about 15 gsm to about 40gsm. Alternatively, the basis weight of the added adhesive may be lessthan about 5 gsm.

[0019] If desired, the abrasive layer may be somewhat translucent. Forexample, the superficial area covered by the abrasive layer may includeopen voids or pores which extend through the axial depth of the abrasivelayer, allowing light to pass through the layer at the pores unhindered.In one embodiment, about 30% of the superficial area of the abrasivelayer surface may include such pores. More specifically, about 50% ofthe superficial area defined by the surface of the abrasive layer mayinclude such pores, making the layer somewhat translucent. Further, theentire laminate of the abrasive layer and a fibrous web may betranslucent, particularly when wet.

[0020] While suitable translucency may be obtained by adjusting fiberdiameter and other structural properties of the abrasive layer (e.g.basis weight, pore size, etc.), steps may be taken, if desired, todecrease the opacity of the polymeric material in the abrasive layerthrough the addition of clarifying agents. In one embodiment, clarifyingagents are added to the polymers used in the abrasive layer, preferablyprior to formation of the abrasive layer. Clarifying agents forpolypropylene may include MoldPro 931 of Crompton Corporation(Greenwich, Conn.), benzylidene sorbitols, CAP20 of Polyvel, Inc.(Hammonton, N.J.), Millad® 3988 clarifying agent from Milliken Chemical(Spartanburg, S.C.),and other agents known in the art. Clarifying agentsgenerally will cause the polymer to have a substantial increase in lighttransmittance as measured according to ASTM D1003, such as at least a20% increase in light transmittance relative to substantially identicalpolymer without the presence of the clarifying agent. (Nucleating agentsare often synonymous with clarifying agents and may also be used tomodify the mechanical properties of the polymer, whether clarificationoccurs or not.) Other additives, fillers, and pigments known in the artmay also be combined with the polymers in the abrasive layers of thepresent invention. Polymeric fibers reinforced with glass or otherminerals, in either fiber or particle form, are within the scope of thepresent invention. For example, mineral or glass-containing fibers orother composite fiber forms may comprise about 50 weight % or moresynthetic polymer, more specifically about 60 weight % or more syntheticpolymer, more specifically still about 80 weight % or more syntheticpolymer, and most specifically from about 90 weight % to about 99 weight% synthetic polymer.

[0021] The abrasive layer may have a relatively open structure thatprovides high permeability, allowing gas or liquid to readily passthrough the abrasive layer. Permeability can be expressed in terms ofAir Permeability measured with the FX 3300 Air Permeability devicemanufactured by Textest AG (Zürich, Switzerland), set to a pressure of125 Pa (0.5 inches of water) with the normal 7-cm diameter opening (38square centimeters), operating in a Tappi conditioning room (73° F., 50%relative humidity). The abrasive layer may have an Air Permeability ofany of the following: about 100 CFM (cubic feet per minute) or greater,about 200 CFM or greater, about 300 CFM or greater, about 500 CFM orgreater, or about 700 CFM or greater, such as from about 250 CFM toabout 1500 CFM, or from about 150 CFM to about 1000 CFM, or from about100 CFM to about 800 CFM, or from about 100 CFM to about 500 CFM.Alternatively, the Air Permeability of the abrasive layer can be lessthan about 400 CFM. In cases wherein the abrasive layer has a basisweight less than 150 gsm, multiple plies of the abrasive layer having acombined basis weight of at least 150 may display an Air Permeability ofabout 70 CFM or greater, or any of the aforementioned values or rangesgiven for a single abrasive layer.

[0022] The dry absorbent layer may have an Air Permeability valuegreater than 30 cubic feet per minute (CFM), such as about 40 CFM orgreater, about 60 CFM or greater, and about 80 CFM or greater.Alternatively, the absorbent layer may have an Air Permeability betweenabout 15 and 30 CFM, or from about 20 CFM to about 80 CFM. Much highervalues are also possible. For example the Air Permeability of theabsorbent layer may be about 150 CFM or greater, 200 CFM or greater, 300CFM or greater, or 400 CFM or greater. By way of example, uncrepedthrough-air dried tissue comprising high-yield fibers has been measuredto have 615 CFM in a 20 gsm web; a sample of Scott®) Towel(Kimberly-Clark Corp., Dallas, Tex.) was measured to have a permeabilityof 140 CFM; a sample of VIVA®) paper towel (Kimberly-Clark Corp.,Dallas, Tex.) was measured to have a permeability of 113 CFM.

[0023] A dry scrubbing product comprising an abrasive layer and anabsorbent layer need not be substantially gas permeable, butnevertheless may have an Air Permeability of any of the following: about10 CFM or greater, about 50 CFM or greater, about 80 CFM or greater,about 100 CFM or greater, about 200 CFM or greater, about 300 CFM orgreater, and about 350 CFM or greater, such as from about 10 CFM toabout 500 CFM, or from about 20 CFM to about 350 CFM, or from about 30CFM to about 250 CFM, or from about 40 CFM to about 400 CFM.

[0024] In one embodiment, a paper web forming the absorbent layer of theproduct may be an uncreped, throughdried paper web and may generallyhave a basis weight greater than about 10 gsm. More specifically, thebasis weight may be between about 20 and about 150 gsm, morespecifically between about 40 gsm and 120 gsm. In addition, the paperweb may comprise high yield pulp fibers. For example, the paper web maycomprise more than about 5 dry weight percent high yield pulp fibers. Inone embodiment, the paper web may comprise between about 15 and about 30dry weight percent high yield pulp fibers. In other embodiments, thepercentage of high-yield fibers in the web may be greater than any ofthe following: about 30%, about 50%, about 60%, about 70%, and about90%. In one embodiment, the absorbent layer of the scrubbing article maybe a multi-ply paper web product. For example, a laminate of two or moretissue layers or a laminate of an airlaid web and a wetlaid tissue maybe formed using adhesives or other means known in the art.

[0025] If desired, the paper web may exhibit translucence when wet. Forinstance, the paper web may have a wet opacity of less than about 98%,specifically less than about 80%, more specifically less than about 60%.In one embodiment, the absorbent layer may be translucent when wet andmay be attached to a translucent abrasive layer for viewing a surfacewhich is being cleaned by the scrubbing product.

[0026] The two primary layers of the scrubbing pad may be attached byany suitable method. For example, the layers may be adhesively orthermally bonded together. In one embodiment, the layers may be bondedtogether with a hotmelt adhesive.

[0027] In addition to the two primary layers of the product, thescrubbing pad may optionally contain other layers or additives. Forexample, the abrasive layer may be made even more abrasive throughvarious possible additives, such as particulate matter like pumice ormicrospheres, included in the layer. Also, the pad may includeadditional layers, such as a hydrophobic barrier layer on the absorbentlayer. A hydrophobic barrier layer may be a permanent layer, such as afilm, applied to the product, or a removable layer, such as ahydrophobic sheet. The hydrophobic barrier may be between the absorbentlayer and the abrasive layer, so as to prevent wetting of part or all ofthe absorbent layer, or optionally may be on the external surface of theabsorbent layer, so as to prevent the hand from getting wet during use.Additionally, the scrubbing product may contain other additivesassociated with either of the primary layers such as soaps, detergents,buffering agents, antimicrobial agents, skin wellness agents, lotions,medications, polishing agents, and the like.

[0028] The scrubbing product of the present invention may be useful inmany different applications. For instance, a scrubbing pad could beuseful as a dishcloth, a scouring pad, a polishing pad, a sanding pad,or a personal cleansing pad, such as an exfoliating pad. In addition,the scrubbing product can be part of a cleaning tool useful for cleaningfloors, walls, windows, toilets, and the like. In certain embodiments,the product of the present invention may include the abrasive layeralone, without any absorbent layer. For example, a meltblown or spunbondabrasive layer alone may be utilized as a scouring pad, a polishing pad,a sanding pad, or a personal cleansing pad such as an exfoliating pad,for instance either with or without the attached absorbent layer.

DEFINITIONS

[0029] As used herein the term “meltblown fibers” means fibers of apolymeric material which are generally formed by extruding a moltenthermoplastic material through a plurality of fine, usually circular,die capillaries as molten threads or filaments into converging highvelocity, usually hot, gas (e.g. air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter.Thereafter, the meltblown fibers may be carried by the high velocity gasstream and are deposited on a collecting surface to form a web ofrandomly dispersed meltblown fibers. Meltblown fibers may be continuousor discontinuous and are generally tacky when deposited onto acollecting surface. In some embodiments, however, low or minimal airflow is used to reduce fiber attenuation and, in some embodiments, topermit neighboring filaments of molten polymer to coalesce (e.g., toadhere along the respective sides of the strands), becoming joined atleast in part along the proximate sides of the neighboring strands toform fibers that are multifilamentary aggregate fibers (i.e. anaggregate fiber formed of two or more polymer strands further definedherein).

[0030] “Papermaking fibers,” as used herein, include all knowncellulosic fibers or fiber mixes comprising cellulosic fibers. Fiberssuitable for making the webs of this invention comprise any natural orsynthetic cellulosic fibers including, but not limited to nonwoodyfibers, such as cotton, abaca, kenaf, sabai grass, flax, esparto grass,straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaffibers; and woody fibers such as those obtained from deciduous andconiferous trees, including softwood fibers, such as northern andsouthern softwood kraft fibers; hardwood fibers, such as eucalyptus,maple, birch, and aspen. Woody fibers may be prepared in high-yield orlow-yield forms and may be pulped in any known method, including kraft,sulfite, high-yield pulping methods and other known pulping methods.Fibers prepared from organosolv pulping methods may also be used. Aportion of the fibers, such as up to 50% or less by dry weight, or fromabout 5% to about 30% by dry weight, may be synthetic fibers such asrayon, polyolefin fibers, polyester fibers, bicomponent sheath-corefibers, multi-component binder fibers, and the like. An exemplarypolyethylene fiber is Pulpex®, available from Hercules, Inc.(Wilmington, Del.). Any known bleaching method may be used. Syntheticcellulose fiber types include rayon in all its varieties and otherfibers derived from viscose or chemically modified cellulose. Chemicallytreated natural cellulosic fibers may be used such as mercerized pulps,chemically stiffened or crosslinked fibers, or sulfonated fibers. Forgood mechanical properties in using papermaking fibers, it may bedesirable that the fibers be relatively undamaged and largely unrefinedor only lightly refined. While recycled fibers may be used, virginfibers are generally useful for their mechanical properties and lack ofcontaminants. Mercerized fibers, regenerated cellulosic fibers,cellulose produced by microbes, rayon, and other cellulosic material orcellulosic derivatives may be used. Suitable papermaking fibers may alsoinclude recycled fibers, virgin fibers, or mixes thereof. In certainembodiments capable of high bulk and good compressive properties, thefibers may have a Canadian Standard Freeness of at least 200, morespecifically at least 300, more specifically still at least 400, andmost specifically at least 500.

[0031] As used herein, “high yield pulp fibers” are those papermakingfibers produced by pulping processes providing a yield of about 65percent or greater, more specifically about 75 percent or greater, andstill more specifically from about 75 to about 95 percent. Yield is theresulting amount of processed fiber expressed as a percentage of theinitial wood mass. Such pulping processes include bleachedchemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP)pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp(TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps,and high yield kraft pulps, all of which leave the resulting fibers withhigh levels of lignin. High yield fibers are well known for theirstiffness (in both dry and wet states) relative to typical chemicallypulped fibers. The cell wall of kraft and other non-high yield fiberstends to be more flexible because lignin, the “mortar” or “glue” on andin part of the cell wall, has been largely removed. Lignin is alsononswelling in water and hydrophobic, and resists the softening effectof water on the fiber, maintaining the stiffness of the cell wall inwetted high yield fibers relative to kraft fibers. The preferred highyield pulp fibers may also be characterized by being comprised ofcomparatively whole, relatively undamaged fibers, high freeness (250Canadian Standard Freeness (CSF)or greater, more specifically 350 CSF orgreater, and still more specifically 400 CSF or greater, such as fromabout 500 to 750 CSF), and low fines content (less than 25 percent, morespecifically less than 20 percent, still more specifically less that 15percent, and still more specifically less than 10 percent by the Brittjar test). In addition to common papermaking fibers listed above, highyield pulp fibers also include other natural fibers such as milkweedseed floss fibers, abaca, hemp, cotton and the like.

[0032] As used herein, the term “cellulosic” is meant to include anymaterial having cellulose as a significant constituent, and specificallycomprising about 20 percent or more by weight of cellulose or cellulosederivatives, and more specifically about 50 percent or more by weight ofcellulose or cellulose derivatives. Thus, the term includes cotton,typical wood pulps, nonwoody cellulosic fibers, cellulose acetate,cellulose triacetate, rayon, viscose fibers, thermomechanical wood pulp,chemical wood pulp, debonded chemical wood pulp, lyocell and otherfibers formed from solutions of cellulose in NMMO, milkweed, orbacterial cellulose, lyocell, and may be viscose, rayon, and the like.Fibers that have not been spun or regenerated from solution may be usedexclusively, if desired, or at least about 80% of the web may be free ofspun fibers or fibers generated from a cellulose solution. Examples ofcellulosic webs may include known tissue material or related fibrousweb, such as wet-laid creped tissue, wet-laid uncreped tissue,pattern-densified or imprinted tissue such as Bounty® paper towels orCharmin® toilet paper made by Procter and Gamble (Cincinnati, Ohio),facial tissue, toilet paper, dry-laid cellulosic webs such as airlaidwebs comprising binder fibers, coform webs comprising at least 20%papermaking fibers or at least 50% papermaking fibers, foam-formedtissue, wipes for home and industrial use, hydroentangled webs such asspunbond webs hydroentangled with papermaking fibers, exemplified by thewebs of U.S. Pat. No. 5,284,703, issued Feb. 8,1994 to Everhart et al.,and U.S. Pat. No. 4,808,467, issued Feb. 28, 1989 to Suskind et al., andthe like. In one embodiment, the cellulosic web can be a reinforcedcellulosic webs comprising a synthetic polymer network such as aspunbond web to which papermaking fibers are added by lamination,adhesive bonding, or hydroentangling, or to which an adhesive such aslatex has been impregnated into the web (e.g., by gravure printing orother known means, exemplified by the VIVA® paper towel ofKimberly-Clark Corp., Dallas, Tex.) to provide high wet or dry tensilestrength to the web. The reinforcing polymer (including adhesive) maycomprise at about 1% or greater of the mass of the cellulosic web, orany of the following: about 5% or greater, about 10% or greater, about20% or greater, about 30% or greater, or about 40% or greater, of themass of the cellulosic web, such as from about 1% to about 50% or fromabout 3% to about 35% of the mass of the cellulosic web.

[0033] As used herein, “void volume” refers to the volume of spaceoccupied by a sample that does not comprise solid matter. When expressedas a percentage, it refers to the percentage of the overall volumeoccupied by the sample that does not comprise solid matter.

[0034] As used herein, “Strength Synergy” and “Stretch Synergy” refer tomeasurements of synergistic improvements in the material properties of acombination of an abrasive layer and a tissue layer when the layers arebonded relative to the unbonded state. When laminates according to thepresent invention are used for scrubbing or other demanding tasks, thedurability of the product may be surprisingly high. At least part of theexcellent performance may be due to a synergy in the material propertiesof the laminate, which may be superior to what one would expect based onthe material properties of the individual components. For example, thetensile strength and stretch properties of an abrasive laminatecomprising a meltblown layer bonded to a tissue web may have asubstantially higher tensile strength than an unbonded combination ofthe same meltblown layer and tissue web together. The ratio of thetensile strength of the bonded laminate relative to the tensile strengthof the unbonded combination of the two or more layers is called the“Strength Synergy.” The tensile measurements are taken with a 3-inch jawwidth, a 4-inch gauge length, in a tensile testing machine with acrosshead speed of 10 inches per minute. Tensile strength is taken asthe maximum load prior to failure, and stretch is the percentageincrease in length at the point of maximum load. The stretch of thelaminate (stretch at the point of failure in tensile testing) may alsobe higher than the stretch of the two or more unbonded layers together.The ratio of the stretch of the bonded laminate relative to the stretchof the unbonded combination of the two or more layers together is calledthe “Stretch Synergy.” Unless otherwise specified, the tensile testingused to determine Strength Synergy and Stretch Synergy is done in themachine direction of the components, or, when the abrasive layer doesnot have a clearly discernible machine direction or has a machinedirection that is not aligned with the machine direction of the tissuein the laminated product, then the tensile testing of the tissuecomponent is taken in the machine direction, which is generally thedirection having the highest tensile strength in a tissue web.

[0035] For some embodiments, the Strength Synergy may be about 1.05 orgreater, more specifically about 1.1 or greater, more specifically stillabout 1.2 or greater, and most specifically about 1.5 or greater, withexemplary ranges of about 1.05 to about 3, about 1.1 to about 2.5, andabout 1.5 to about 4. For some embodiments, the Stretch Synergy may beabout 1.1 or greater, more specifically about 1.3 or greater, morespecifically still about 1.5 or greater, and most specifically about 1.8or greater, with exemplary ranges of about 1.3 to about 3, about 1.5 toabout 2.5, and about 1.5 to about 2. A laminate with a Stretch Synergysubstantially greater than 1 may have but need not have a StrengthSynergy substantially greater than 1. Likewise, a laminate with aStrength Synergy substantially greater than 1 may have but need not havea Stretch Synergy substantially greater than 1.

[0036] “Overall Surface Depth” is a measure of the topography of asurface, indicative of a characteristic height different betweenelevated and depressed portions of the surface. The optical techniqueused for measuring Overall Surface Depth is described hereafter.

BRIEF DESCRIPTION OF THE FIGURES

[0037] A full and enabling disclosure of the present invention,including the best mode thereof to one of ordinary skill in the art, isset forth more particularly in the remainder of the specification,including reference to the accompanying figures in which:

[0038]FIG. 1 is a schematic diagram of one embodiment of a process linefor making the abrasive layer of the present invention;

[0039]FIG. 2 is a diagram of one embodiment of a process for forminguncreped throughdried paper webs as may be used in the presentinvention;

[0040]FIG. 3 is a schematic diagram of one embodiment of a process linefor making the composite construction of the present invention;

[0041]FIG. 4 is an embodiment of a process for combining the layers ofthe composite construction of the present invention;

[0042]FIG. 5 is another embodiment of a process for combining the layersof the composite construction of the present invention;

[0043]FIG. 6 is a perspective view of one embodiment of a scrubbing padof the present invention;

[0044]FIG. 7 is a cross-sectional view of one embodiment of thescrubbing pad of the present invention;

[0045]FIG. 8 is a cross-sectional view of another embodiment of thescrubbing pad of the present invention;

[0046]FIG. 9 is a cross-sectional view of another embodiment of thescrubbing pad of the present invention;

[0047]FIG. 10 is a perspective view of one embodiment of a cleaning toolof the present invention wherein the scrubbing pad is held on a rigidgripping device;

[0048]FIG. 11 depicts cross-sections of a fiber formed from a singlepolymeric strand and a multifilamentary aggregate formed from sixcoalesced strands;

[0049]FIG. 12 depicts a cut-away portion of a meltblown die;

[0050]FIG. 13 is a plan-view micrograph of a meltblown-tissue laminateaccording to the present invention;

[0051]FIGS. 14A and 14B are cross-sectional micrographs of ameltblown-tissue laminate showing multifilamentary aggregates;

[0052]FIG. 15 is a display of topographical data in a height map for ameltblown-tissue laminate also showing a profile line extracted from theheight map;

[0053]FIG. 16 is a display of topographical data from the same heightmap shown in FIG. 15 but displaying a different profile line;

[0054]FIG. 17 is a plan-view micrograph of meltblown-tissue laminateshowing multifilamentary aggregates;

[0055]FIG. 18 is a micrograph of the cross-section of themeltblown-tissue laminate of FIG. 17;

[0056]FIG. 19 is a plan-view micrograph of a meltblown-tissue laminate;

[0057]FIG. 20 is a display of topographical data in a height map foranother meltblown-tissue laminate according to the present invention;

[0058]FIG. 21 is a plan-view micrograph of a meltblown-tissue laminatecorresponding to that shown in FIG. 20;

[0059]FIG. 22 is a micrograph of the cross-section of themeltblown-tissue laminate of FIG. 21;

[0060]FIG. 23 depicts a cross-section of one embodiment of an articleaccording to the present invention having heterogeneous properties inthe abrasive layer;

[0061]FIG. 24 depicts a cross-section of an article according to thepresent invention having nonuniform properties in each of two abrasivelayers on opposing sides of the fibrous absorbent layer; and

[0062]FIG. 25 depicts a starting point for an Abrasive Index Test.

[0063] Repeat use of reference characters in the present specificationand drawings is intended to represent same or analogous features orelements of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0064] Reference now will be made in detail to the embodiments of theinvention, one or more examples of which are set forth below. Eachexample is provided by way of explanation of the invention, notlimitation of the invention. In fact, it will be apparent to thoseskilled in the art that various modifications and variations may be madein the present invention without departing from the scope or spirit ofthe invention. For instance, features illustrated or described as partof one embodiment, may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncover such modifications and variations as come within the scope of theappended claims and their equivalents.

[0065] In general, the present invention is directed to disposablescrubbing pads which are suitable for use in a wide variety ofapplications, including household cleaning and personal careapplications. For example, the scrubbing products of the presentinvention may be suitable for use as a dishcloth, a general purposecleaning cloth, a scouring or polishing pad, or a personal care product,such as an exfoliating pad, for instance. In certain embodiments, thescrubbing products of the present invention can be used to remove layersof a surface, for example in a sanding or polishing application.

[0066] The scrubbing pads of the present invention are generally of amulti-layer construction and include a nonwoven abrasive layer securedto an absorbent layer which includes a nonwoven paper web. For instance,the abrasive layer may be a porous, flexible, meltblown web and may bethermally bonded to a high bulk, absorbent paper web, such as anuncreped, through-air dried (UCTAD) paper web.

[0067] The two distinct layers of the composite scrubbing pad may offercleaning advantages beyond those known in other composite scrubbingarticles, and may do so at a much lower cost. Other advantages aregained by the disposable scrubbing pads as well. For instance, the softpaper web and flexibility of the pad may make the article much morecomfortable to hold during cleaning than previously known compositescrubbing articles. Additionally, the pads may be shaped so as to beattachable to a rigid gripping device, forming a convenient cleaningtool for either heavy or light scrubbing, as desired by the user. Forexample, a cleaning tool capable of holding the scrubbing product of thepresent invention could be used for cleaning floors, walls, windows,toilets, ceiling fans, and the like as well as for cleaning surfaces bypolishing or sanding a surface.

[0068] If desired, the scrubbing pads may optionally include variousadditives, such as cleaning agents or medications, which may enhance theperformance of the pads. Moreover, the scrubbing pads may exhibittranslucence when wet, such that the user may see the surface beingcleaned while scrubbing continues. Of particular advantage, it has beendiscovered that a synergy may occur between the component layers of thecomposite structure of the present invention, and the scrubbing pads mayexhibit mechanical properties greater than the sum of the mechanicalproperties of the individual layers. For example, the tensile strengthand the durability, among other mechanical properties, may be greater inthe composite structure than the sum of the same properties in theindividual layers. Similarly, the abrasiveness of the pad at theabrasive surface may be enhanced due to the texture of the attachedabsorbent layer.

[0069] In general, the abrasive layer of the scrubbing pads of thepresent invention may include a material which is formed into an open,porous structure and has enough strength and hardness to form a rough,scratchy surface on the pad. Suitable materials are abundant and may beeither natural or synthetic materials. Possible exemplary materials mayinclude any known abrasive materials formed into the desired openstructure. Possible synthetic materials may be polymeric materials, suchas, for instance, meltspun nonwoven webs formed of molten or uncuredpolymer which may then harden to form the desired abrasive layer.

[0070] Other materials may optionally be used as the abrasive layer ofthe present invention. For example, other materials used as abrasives inknown commercial scrubbing products could be used, such as aperturednylon covers, nylon networks, and materials similar to those found inother abrasive products such as, for instance, SCOTCHBRITE pads of 3MCorp. (Minneapolis, Minn.).

[0071] The materials and processes used to form the abrasive layer ofthe scrubbing pad may be chosen and designed with the desired end use ofthe product in mind. For example, a scrubbing pad designed as a personalcare product, such as a face-washing pad, may include an abrasive layerwhich is softer and less abrasive than a scrubbing pad for use inhousehold cleaning applications. Thus, the raw materials, additives,fiber diameter, layer density and stiffness, etc. may all vary dependingon the desired characteristics of the final product.

[0072] In one embodiment, the abrasive layer of the scrubbing pad mayinclude a nonwoven meltblown web, such as may be formed using athermoplastic polymer material. Generally, any suitable thermoplasticpolymer that may be used to form meltblown nonwoven webs may be used forthe abrasive layer of the scrubbing pads. A non-exhaustive list ofpossible thermoplastic polymers suitable for use include polymers orcopolymers of polyolefins, polyesters, polypropylene, high densitypolypropylene, polyvinyl chloride, vinylidene chloride, nylons,polytetrafluoroethylene, polycarbonate, poly(methyl) acrylates,polyoxymethylene, polystyrenes, ABS, polyetheresters,, or polyamides,polycaprolactan, thermoplastic starch, polyvinyl alcohol, polylacticacid, such as for example polyesteramide (optionally with glycerin as aplasticizer), poluphenylsulfide (PPS), poly ether ether ketone (PEEK),polyvinylidenes, polyurethane, and polyurea. For instance, in oneembodiment, the abrasive layer may include meltblown nonwoven websformed with a polyethylene or a polypropylene thermoplastic polymer.Polymer alloys may also be used in the abrasive layer, such as alloyfibers of polypropylene and other polymers such as PET. Compatibilizersmay be needed for some polymer combinations to provide an effectiveblend. In one embodiment, the abrasive polymer is substantially free ofhalogenated compounds,. In another embodiment, the abrasive polymer isnot a polyolefin, but comprises a material that is more abrasive thansay, polypropylene or polyethylene (e.g. having flexural modulus ofabout 1200 MPa and greater, or a Shore D hardness of 85 or greater).

[0073] In addition to being coarse, the fibers of the abrasive layer mayhave a high elastic modulus, such as an elastic modulus roughly equal toor greater than that of polypropylene such as about 1,000 MPa orgreater, specifically about 2,000 MPa or greater, more specificallyabout 3,000 MPa or greater, and most specifically about 5,000 MPa orgreater. By way of example, phenol plastics may have elastic moduli ofabout 8000 MPa, and apolyamide (nylon 6,6) reinforced with 15% glassfiber has a reported elastic modulus of about 4,400 MPa (whereas theelastic modulus is about 1,800 MPa without the glass reinforcement).

[0074] The fibers of the abrasive layers can be elastomeric ornon-elastomeric, as desired (e.g., crystalline or semi-crystalline). Inaddition, the abrasive layer may comprise a mix of elastomeric fibersand non-elastomeric fibers.

[0075] For some polymer groups, an increased melting point may correlatewith improved abrasive features. Thus, in one embodiment, the abrasivefibers may have a melting point greater than 120° C., such as about 140°C. or greater, about 160° C. or greater, about 170° C. or greater, about180° C. or greater, or about 200° C. or greater, exemplified by thefollowing ranges: from about 120° C. to about 350° C., from about 150°C. to about 250° C., or from about 160° C. to about 210° C.

[0076] Another measure that may be indicative of good abrasiveproperties is Shore Hardness D, as measured with standard test methodASTM D 1706. In general, suitable polymeric material of the abrasivelayer may have a Shore Hardness D of about 50 or greater, such as about65 or greater, or more specifically, about 70 or greater, or mostspecifically about 80 or greater. Polypropylene, for example, typicallyhas Shore D hardness values from about 70 to about 80.

[0077] In one embodiment, the polymeric material in the abrasive layermay have a flexural modulus of about 500 MPa or greater and a Shore Dhardness of about 50 or greater. In an alternative embodiment, thepolymeric material may have a flexural modulus of about 800 MPa orgreater and a Shore D hardness of about 50 or greater.

[0078] In one embodiment, the abrasive layer of the scrubbing pad mayinclude a nonwoven meltblown web, such as may be formed using athermoplastic polymer material. Generally, any suitable thermoplasticpolymer that may be used to form meltblown nonwoven webs may be used forthe abrasive layer of the scrubbing pads. A non-exhaustive list ofpossible thermoplastic polymers suitable for use include polymers orcopolymers of polyolefins, polyesters, polyetheresters, nylons, orpolyamides, polycaprolactan, thermoplastic starch, polyvinyl alcohol,polyactic acid, such as for example polyesteramide (optionally withglycerin as a plasticizer). For instance, in one embodiment, theabrasive layer may include meltblown nonwoven webs formed with apolyethylene or a polypropylene thermoplastic polymer.

[0079] In one embodiment, the polymeric fibers of the abrasive layer aresubstantially free of plasticizers, or may have 33 weight percentplasticizer or less, more specifically about 20 weight percentplasticizer or less, more specifically about 3 weight percentplasticizer or less. The dominant polymer in the polymeric fibers mayhave a molecular weight of any of the following: about 100,000 orgreater, about 500,000 or greater, about 1,000,000 or greater, about3,000,000 or greater, and about 5,000,000 or greater.

[0080] The abrasive layer may comprise fibers of any suitablecross-section. For example, the fibers of the abrasive layer may includecoarse fibers with circular or non-circular cross-sections. Moreover,non-circular cross-sectional fibers may include grooved fibers ormulti-lobal fibers such as, for example, “4DG” fibers (specialty PETdeep grooved fibers, with an eight-legged cross-section shape).Additionally, the fibers may be single component fibers, formed of asingle polymer or copolymer, or may be multi-component fibers.

[0081] In an effort to produce an abrasive layer having desirablecombinations of physical properties, in one embodiment, nonwovenpolymeric fabrics made from multi-component or bicomponent filaments andfibers may be used. Bicomponent or multi-component polymeric fibers orfilaments include two or more polymeric components which remaindistinct. The various components of multi-component filaments arearranged in substantially distinct zones across the cross-section of thefilaments and extend continuously along the length of the filaments. Forexample, bicomponent filaments may have a side-by-side or core andsheath arrangement. Typically, one component exhibits differentproperties than the other so that the filaments exhibit properties ofthe two components. For example, one component may be polypropylenewhich is relatively strong and the other component may be polyethylenewhich is relatively soft. The end result is a strong yet soft nonwovenfabric.

[0082] In one embodiment, the abrasive layer comprises metallocenepolypropylene or “single site” polyolefins for improved strength andabrasiveness. Exemplary single-site materials are available from H. B.Fuller Company, Vadnais Heights, Minn.

[0083] In another embodiment, the abrasive layer includes a precursorweb comprising a planar nonwoven substrate having a distribution ofattenuated meltable thermoplastic fibers such as polypropylene fibersthereon. The precursor web may be heated to cause the thermoplasticfibers to shrink and form nodulated fiber remnants that impart anabrasive character to the resultant web material. The nodulated fiberremnants may comprise between about 10% and about 50% by weight of thetotal fiber content of the web and may have an average particle size ofabout 100 micrometers or greater. In addition to the fibers that areused to form nodulated remnants, the precursor web may containcellulosic fibers and synthetic fibers having at least one componentwith a higher melting point than polypropylene to provide strength. Theprecursor web may be wet laid, air laid, or made by other methods. Inone embodiment, the precursor web is substantially free of papermakingfibers. For example, the precursor web may be a fibrous nylon webcontaining polypropylene fibers (e.g., a bonded carded web comprisingboth nylon fibers and polypropylene fibers).

[0084] The abrasive layer may also be apertured to improve fluid accessto the absorbent layer of the article. Pin apertured meltblown webs, forexample, may have increased abrasiveness due to the presence ofapertures.

[0085] The material used to form the abrasive layer may also containvarious additives as desired. For example, various stabilizers may beadded to a polymer, such as light stabilizers, heat stabilizers,processing aides, and additives that increase the thermal agingstability of the polymer. Further, auxiliary wetting agents, such ashexanol, antistatic agents such as a potassium alkyl phosphate, andalcohol repellants such as various fluoropolymers (e.g., DuPontRepellent 9356H) may also be present. Desired additives may be includedin the abrasive layer either through inclusion of the additive to apolymer in the die or alternatively through addition to the abrasivelayer after formation, such as through a spraying process.

[0086] For exemplary purposes, one embodiment of a system for forming ameltblown nonwoven web as may be used in the abrasive layer of thescrubbing pad is illustrated in FIG. 1. As shown, the system includes aforming machine generally 110 which may be used to produce a meltblownweb 32 in accordance with the present invention. Particularly, theforming machine 110 includes an endless foraminous-forming belt 114wrapped around rollers 116 and 118 so that the belt 114 is driven in thedirection shown by the arrows.

[0087] The forming belt 114 may be any suitable forming belt and, ifdesired, may provide additional three-dimensional texture to themeltblown layer. Added texture may affect the abrasiveness of the layer.For example, a high degree of surface texture in the meltblown layer maybe achieved by forming a meltblown layer on a high dimension formingfabric, such as those available from Lindsay Wire Company. FIG. 8 is across section of one embodiment of the present invention illustrating ahighly texture meltblown layer 32 such as could be formed on a highlytextured forming fabric. The highly texture meltblown layer may then beattached to an absorbent layer 34 in forming the scrubbing pad of thepresent invention.

[0088] The forming machine system of FIG. 1 may also include a die 120which is used to form fibers 126. The throughput of the die 120 isspecified in pounds of polymer melt per inch of die width per hour(PIH). As a thermoplastic polymer exits the die 120, high-pressurefluid, usually air, attenuates and spreads the polymer stream to formfibers 126. The fibers 126 may be randomly deposited on the forming belt114 and form a meltblown layer 32.

[0089] In the manufacture of conventional meltblown materials, highvelocity air is usually used to attenuate the polymeric strands tocreate fine, thin fibers. In the present invention, by adjusting the airflow system, such as by increasing the air flow area or otherwisedecreasing the velocity of the air stream immediately adjacent themolten polymeric strands as they emerge from the meltblown die head, itis possible to prevent substantial attenuation of the fiber diameter (orreduce the degree of fiber attenuation). Limiting the attenuation of thefiber diameter may increase fiber coarseness, which may increase theabrasiveness of the layer formed by the fibers.

[0090] Additionally, the airflow near the die exit may be used toagitate and spread the polymeric fibers in a manner than may be highlynon-uniform on the forming belt. The large degree of non-uniformity ofthe lay-down of coarse meltblown fibers on the belt may be manifest in aweb which may display variations in thickness and variations in basisweight across the surface of the web, i.e., an uneven surface may becreated on the web, which may increase the abrasiveness of the layerformed by the fibers.

[0091] In addition, non-uniform spread of the fibers during formation ofthe web may create a web with increased void space within the web. Forexample, an open network of fibers may be formed which may have openvoids that occupy a substantial portion of the layer. For instance, thevoid volume of the abrasive layer may be greater than about 10%,particularly greater than about 50%, and more particularly greater thanabout 60% of the volume of the material. These open void materials mayinherently have good scrubbing properties.

[0092] The void space, or pores, created in the web may also producevariations in opacity across the web such that the abrasive layer formedby the web may be somewhat translucent. Due to the random lay down ofthe fibers and the resulting open structure of the abrasive layer, manyof the pores formed in the web may extend across the entire depth of thelayer, permitting light to pass through the layer unhindered andproviding a degree of translucence to the abrasive layer. In certainembodiments, more than about 30% of the surface area of the abrasivelayer may include open void space which extends across the axial depthof the layer. More specifically, more than about 50% of the surface areaof the abrasive layer may include open void space extending across theaxial depth of the layer, providing a high degree of translucence to theabrasive layer. As such, a significant percentage of the superficialarea of the abrasive layer may be occupied by openings or pores throughwhich the underlying absorbent layer may be seen. For example, about 10%or greater, specifically about 20% or greater, more specifically about40% or greater, and most specifically about 55% or greater of thesuperficial area of the abrasive layer (the surface area seen in planview from above) may be occupied by openings through which theunderlying absorbent layer may be seen. Additionally, the abrasive layermay be formed of a translucent polymer, which may increase thetranslucence of the layer.

[0093] Expressed on a percentage basis, the standard deviation ofopacity for data points averaged over 5-mm square sections, may be about5% of greater, more specifically about 10% or greater, more specificallyabout 20% or greater, and most specifically about 30% or greater, suchas from about 8% to about 60%, or from 12% to about 50%.

[0094] While suitable translucency may be obtained by adjusting fiberdiameter and other structural properties of the abrasive layer (e.g.basis weight, pore size, etc.), steps may be taken, if desired, todecrease the opacity of the polymer material in the abrasive layerthrough the addition of clarifying agents. In one embodiment, clarifyingagents are added to the polymers used in the abrasive layer, preferablyprior to formation of the abrasive layer. Clarifying agents forpolypropylene may include MoldPro 931 of Crompton Corporation(Greenwich, Conn.), benzylidene sorbitols, CAP20 of Polyvel, Inc.(Hammonton, N.J.), Millad® 3988 clarifying agent from Milliken Chemical(Spartanburg, S.C.), and other agents known in the art. Clarifyingagents generally will cause the polymer to have a substantial increasein light transmittance as measured according to ASTM D1003, such as atleast a 20% increase in light transmittance relative to substantiallyidentical polymer without the presence of the clarifying agent.(Nucleating agents are often synonymous with clarifying agents and mayalso be used to modify the mechanical properties of the polymer, whetherclarification occurs or not.) Other additives, fillers, and pigmentsknown in the art may also be combined with the polymers in the abrasivelayers of the present invention. Polymeric fibers reinforced with glassor other minerals, in either five or particle form, are within the scopeof the present invention. For example, mineral or glass-containingfibers or other composite fiber forms may comprise about 50 weight % ormore synthetic polymer, more specifically about 60 weight % or moresynthetic polymer, more specifically still about 80 weight % or moresynthetic polymer, and most specifically from about 90 weight % to add99 weight % synthetic polymer.

[0095] In general, thermoplastic polymer fibers in the abrasive layermay be greater than about 30 microns in mean diameter. Morespecifically, thermoplastic fibers may be between about 40 microns andabout 800 microns in mean diameter, such as from about 50 microns to 400microns, more specifically still from about 60 microns to 300 microns,and most specifically from about 70 microns to about 250 microns. Suchfibers are substantially coarser than the fibers of conventionalmeltblown webs, and the added coarseness is generally helpful inincreasing the abrasive characteristics of the web.

[0096] The fibers forming the meltblown web may be long enough so as tosupport the open network of the layer. For example, the fibers may havea fiber length of at least about one centimeter. More specifically, thefibers may have a characteristic fiber length of greater than about 2cm.

[0097] If desired, the fibers may optionally be formed to includeabrasion enhancing features, such as inclusion of filler particles, forexample microspheres, granules of pumice or metal, treatment withmeltblown “shot”, and the like.

[0098] Microspheres may be from about 10 microns to about 1 mm indiameter and typically have a shell thickness of from about 1 to about 5microns, while macrospheres (which may also be used in some embodiments)may have diameters greater than about 1 mm. Such materials may includemicrobeads of metal, glass, carbon, mica, quartz or other minerals,plastic such as acrylic or phenolic, including acrylic microspheresknown as PM 6545 available from PQ Corporation of Pennsylvania, andhollow microspheres such as the cross-linked acrylate SunSpheres™ of ISPCorporation (Wayne, N.J.) and similar hollow spheres as well asexpandable spheres such as Expancel® microspheres (Expancel,Stockviksverken, Sweden, a division of Akzo Nobel, Netherlands), and thelike.

[0099] In one embodiment of the present invention, the abrasive layermay be made from a nonwoven meltspun web, such as a meltblown webtreated with a meltblown “shot”. Meltblown shot is a coarse nonuniformlayer applied in a meltblown process deliberately operated to generaterandom globules of the polymer (typically polypropylene or anotherthermoplastic) interconnected with strands. If desired, the shot may bedistinctly colored to make the abrasive element readily visible.

[0100] Optionally, the abrasive layer of the present invention may beformed from two or more different fiber types. For instance, theabrasive layer may be formed of different fiber types formed ofdifferent polymers or different combinations of polymers. Additionally,the abrasive layer may be formed of different fiber types includingfibers of different orientations, i.e. curled or straight fibers, orfibers having different lengths or cross sectional diameters from eachother. For example, die 120 may be a multi-section die and includedifferent polymer material in different sections which may be fedthrough the die 120 and form distinctly different fibers which may thenbe mixed and heterogeneously distributed on forming belt 114.Alternatively, two or more different meltblown sub-layers may be formedand bonded together to form an abrasive layer with a fairly uniform,homogeneous distribution of different fiber types.

[0101] In one embodiment, the abrasive layer of the present inventionmay include multifilamentary aggregates of individual polymeric strands.

[0102] As used herein, the term “multifilamentary aggregate” refers to ameltblown fiber that is actually an aggregate of two or more polymerstrands formed by at least the partial coalescence (adhesion) ofadjacent molten polymer strands ejected from adjacent holes on ameltblown die, which may be achieved, for example, under circumstancesin which the turbulence created by air jets is substantially lower thanin normal meltblown operation, thereby allowing two or more adjacentstrands to come into contact and become joined together along at least aportion of the length of the strands. For instance, the individualstrands forming the multifilamentary aggregate fiber may be joined sideby side for a distance greater than about 5 mm, along the length of thefiber. As such, bicomponent fibers, multi-lobal fibers, and the like,which are extruded as a single fiber with multiple polymers or complexshapes are not to be confused with the mitifilamentary aggregate fibersof the present invention, which include adjacent polymer strandsextruded or ejected from adjacent holes in a meltblown die and onlyadhere together after exiting the die.

[0103] The holes of the meltblown die may be in one or more rows. Whenmore than one row of holes is present in a die, the holes may bestaggered or aligned, or distributed in other ways known in the art. Thedie holes may be any desired shape in order to form individual strandsof a desired cross sectional shape. In one embodiment, the die holes maybe circular such that the polymer strands, before aggregation to formthe aggregate fibers of the present invention are substantially circularin cross section. Even after adhesion together, the substantiallycircular individual polymer strands may retain elements of theirindividual circular cross sections, as can be seen in FIGS. 14A and 14B.

[0104] Multifilamentary aggregates may be substantially ribbon-like incharacter, particularly when three or more strands from adjacentmeltblown holes aligned in a line adhere to each other in asubstantially parallel array (i.e., parallel to each other with the lineformed by connecting the center points of consecutive strands being anapproximately straight line). For example, FIG. 11 illustrates amultifilamentary aggregate formed of six individual polymer strandsadhered in a substantially parallel array. The width of themultifilamentary aggregate may be nearly as great as the number ofstrands in the multifilamentary aggregates multiplied by the diameter ofa single strand, though due to the fusion of portions of the joinedstrands and due to staggering of the strands in some cases, the width isgenerally a fraction of the product of the number of strands and thesingle strand diameter (or average single strand diameter). Thisfraction may be from about 0.2 to about 0.99, specifically from about0.4 to about 0.97, more specifically from about 0.6 to about 0.95, andmost specifically from about 0.7 to about 0.95. In one embodiment, themajor axis of the non-circular multifilament aggregate fiber crosssection can be greater than about 30 microns.

[0105] The number of strands in the multifilamentary aggregates mayrange from 2 to about 50, specifically from 2 to about 30, morespecifically from 2 to about 20, and most specifically from about 3 toabout 12. Multifilamentary aggregates may have a number-weighted averagestrand count of 3 or more, 4 or more, 5 or more, or 6 or more. Ameltblown web comprising multifilamentary aggregates may havemultifilamentary aggregates comprising 5% or greater of the mass of theweb (such as multifilamentary aggregates with three strands or morecomprising 5% or greater of the mass of the web). For example, the massfraction of the web consisting of multifilamentary aggregates may beabout 10% or greater, about 20% or greater, about 30% or greater, about40% or greater, about 50% or greater, about 60% or greater, about 70% orgreater, about 80% or greater, about 90% or greater, or substantially100%. These ranges may apply to multifilamentary aggregates in general,or to multifilamentary aggregates having at least 3 strands, 4 strands,5 strands, or 6 strands.

[0106]FIG. 11 depicts cross-sections of a polymeric fiber 126 formedfrom a single polymeric strand 238 in an operation such as meltblown,and for comparison depicts a cross-section of a multifilamentaryaggregate 240 formed by the partial coalescence of six strands 238 toyield a ribbon-like structure. The region where two strands 238 arejoined together may comprise a cusp 243.

[0107] The smallest rectangle 241 that may completely enclose thecross-section of the multifilamentary aggregate 240 has a width W and aheight H. The width W is the width of the multifilamentary aggregate andthe height H is the height of multifilamentary aggregate. The aspectratio of the multifilamentary aggregate is the ratio W/H. The aspectratio of multifilamentary aggregates in the present invention may beabout 2 or greater, about 3 or greater, about 4 or greater, about 5 orgreater, or about 6 or greater, such as from about 3 to about 12.

[0108] The strands 238 of the multifilamentary aggregate 240 may remainsubstantially parallel throughout the length of the fiber (amultifilamentary aggregate 240), or may persist for a distance and thensplit into two or more groups of smaller multifilamentary aggregates orindividual strands 238. The strands 238 of the multifilamentaryaggregate 240 may remain joined to one another along their sides for adistance of about 1 mm or greater, 5 mm or greater, 10 mm of greater, 20mm or greater, or 50 mm or greater.

[0109] The forming belt 114 may be any suitable forming belt and, ifdesired, may provide texture to the meltblown layer, which may alsoaffect the abrasiveness of the layer. For example, a high degree ofsurface texture in the meltblown layer may be achieved by forming themeltblown layer on a high dimension forming fabric, such as thoseavailable from the Lindsay Wire Company. In another embodiment, theabrasive layer may be formed directly on the fibrous absorbent web (notshown), such as a textured tissue web or other cellulosic web, which maybe carried by a fabric. FIG. 8 is a cross section of one embodiment ofthe present invention with a highly textured meltblown layer 32 attachedto a relatively flat absorbent layer 34. Alternatively, the forming belt114 may be relatively flat and produce a flat meltblown layer 32, as isillustrated in FIG. 7.

[0110] The abrasive layer may have a suitable fiber basis weight andformation so as to provide good scrubbing characteristics to thecomposite pad structure while remaining flexible. For example, ameltblown web forming the abrasive layer may have a basis weight ofgreater than about 10 gsm. More specifically, the meltblown web may havea basis weight of between about 25 gsm and about 400 gsm, morespecifically between about 30 gsm and about 200 gsm, and mostspecifically between about 40 gsm and 160 gsm The meltblown web may havea density ranging from any of about 0.02 grams/cubic centimeter (g/cc),0.04 g/cc, 0.06 g/cc, 0.1 g/cc, 0.2 g/cc, 0.4 g/cc, 0.6 g/cc, and 0.8g/cc to any of about 0.1 g/cc, 0.3 g/cc, 0.5 g/cc, and 1 g/cc (othervalues and ranges known in the art may also be within the scope of thepresent invention). In one embodiment, the abrasive layer may be formedsuch that when the pad is put under pressure, as when a surface is beingscrubbed by contact with the abrasive layer, the surface may besubstantially in contact with only the meltblown layer of the pad.

[0111] As previously discussed, the web may be formed with variations inthickness and basis weight across the web so as to produce a web with anuneven, more abrasive surface. Thickness variations across the surfaceof the web may be measured with a platen 0.6 inches in diameter that ispressed against the sample with a load of 7.3 psi (applied pressure of50 kPa) as it resides on a solid surface, wherein the displacement ofthe platen relative to the solid surface indicates the local thicknessof the sample. Repeated measurements at different locations on thesample may be used to obtain a distribution of local thicknessmeasurements from which a standard deviation may be calculated. Abrasivelayers of the present invention may have a standard deviation in thisthickness measurement of at least about 0.2 mm, specifically at leastabout 0.6 mm, more specifically at least about 0.8 mm, an mostspecifically at least 1.0 mm. Expressed on a percentage basis, thestandard deviation of basis weight for data points averaged over 5-mmsquare sections, may be about 5% or greater, more specifically about 10%or greater, more specifically still about 20% or greater, and mostspecifically about 30% or greater, such as from about 8% to about 60%,or from 12% to about 50%.

[0112] The abrasiveness of the abrasive layer may further be enhanced bythe topography of the abrasive layer. For example, the abrasive layermay have a plurality of elevated and depressed regions due to nonuniformbasis weight, nonuniform thickness, or due to the three-dimensionaltopography of an underlying fibrous web such as a textured wetlaidtissue web. The elevated and depressed regions may be spaced apartsubstantially periodically in at least one direction such as the machinedirection or the cross direction with a characteristic wavelength ofabout 2 mm or greater, more specifically about 4 mm or greater, andhaving a characteristic height difference between the elevated anddepressed regions of at least 0.3 mm or greater, more specifically about0.6 mm or greater, more specifically still about 1 mm or greater, andmost specifically about 1.2 mm ore greater.

[0113] In another embodiment, the abrasive layer may include a precursorweb comprising a planar nonwoven substrate having a distribution ofattenuated meltable thermoplastic fibers such as polypropylene fibersthereon. The precursor web may be heated to cause the thermoplasticfibers to shrink and form nodulated fiber remnants that impart anabrasive character to the resultant web material. The nodulated fiberremnants may comprise between about 10% and about 50% by weight of thetotal fiber content of the web and may have an average particle size ofabout 100 micrometers or greater. In addition to the fibers that areused to form nodulated remnants, the precursor web may containcellulosic fibers and synthetic fibers having at least one componentwith a higher melting point than polypropylene to provide strength. Theprecursor web may be wet laid, air laid, or made by other methods. Inone embodiment, the precursor web is substantially free of papermakingfibers. For example, the precursor may be a fibrous nylon web containingpolypropylene fibers (e.g., a bonded carded web comprising both nylonfibers and polyproylene fibers).

[0114] The abrasive layer may also be apertured to improve fluid accessto the absorbent layer of the article. Pin apertured meltblown webs, forexample, may have increased abrasiveness due to the presence of theapertures.

[0115] Other materials may optionally be used as the abrasive layer ofthe present invention. For example, other materials used as abrasives inknown commercial scrubbing products could be used, such as aperturednylon covers, nylon networks, and materials similar to those found inother abrasive products such as, for instance, SCOTCHBRITE pads of 3MCorp. (Minneapolis, Minn.).

[0116] In accordance with the present invention, an abrasive layer maybe secured to one or more absorbent layers, such as that formed by anonwoven paper web, to form a disposable scrubbing pad. When laminatesaccording to the present invention are used for scrubbing or otherdemanding tasks, the durability of the product may be surprisingly high.At least part of the excellent performance may be due to a synergy inthe material properties of the laminate, which may be superior to whatone would expect based on the material properties of the individualcomponents. For example, the tensile strength and stretch properties ofan abrasive laminate comprising a meltblown layer bonded to a tissue webmay have a substantially higher tensile strength than an unbondedcombination of the same meltblown layer and tissue web together.

[0117] For some embodiments, the Strength Synergy may be about 1.05 orgreater, more specifically about 1.1 or greater, more specifically stillabout 1.2 or greater, and most specifically about 1.5 or greater, withexemplary ranges of about 1.05 to about 3, about 1.1 to about 2.5, andabout 1.5 to about 4. For some embodiments the Stretch Synergy may beabout 1.1 or greater, more specifically about 1.3 or greater, morespecifically still about 1.5 or greater, and most specifically about 1.8or greater, with exemplary ranges of about 1.3 to about 3, about 1.5 toabout 2.5, and about 1.5 to about 2. A laminate with a Stretch Synergysubstantially greater than 1 may have but need not have a StrengthSynergy substantially greater than 1. Likewise, a laminate with aStrength Synergy substantially greater than 1 may have but need not havea Stretch Synergy substantially greater than 1.

[0118] The paper web of the absorbent layer is generally a web thatcontains high levels of bulk. Further, the web may have a substantialamount of wet strength and wet resilience for use in wet environments.The paper web, if desired, may also be highly textured and have athree-dimensional structure, similar to the abrasive layer, aspreviously discussed. For instance, the paper web may have an OverallSurface Depth of greater than about 0.2 mm, and particularly greaterthan about 0.4 mm. In one embodiment, the paper web may be a commercialpaper towel, such as a SCOTT® Towel or a VIVA® Towel, for instance.SCOTT® Towel, for example, has a wet:dry tensile strength ratio (ratioof the wet tensile strength to the dry tensile strength, taken in thecross direction) typically greater than 30% (e.g., one set ofmeasurements gave a value of 38%), and VIVA® Towel has a wet:dry tensilestrength ratio typically greater than 60% (e.g., one set of measurementsgave a value of 71%). Wet:dry tensile strength ratios may also begreater than 10%, 20%, 40%, or 50%.

[0119] In one embodiment, the paper web may be a textured web which hasbeen dried in a three-dimensional state such that the hydrogen bondsjoining fibers were substantially formed while the web was not in aflat, planar state. For instance, the web may be formed while the web ison a highly textured through drying fabric or other three-dimensionalsubstrate.

[0120] In general, the uncreped throughdried paper web may have a basisweight of greater than about 25 gsm. Specifically, the paper web mayhave a basis weight greater than about 40 gsm, more specifically greaterthan about 50 gsm. If desired, the web may include a wet strength agentand/or at least about five percent (5%) by weight of high-yield pulpfibers, such as thermomechanical pulp. In addition to high-yield pulpfibers, the web may contain papermaking fibers, such as softwood fibersand/or hardwood fibers. In one embodiment, the web is made entirely fromhigh-yield pulp fibers and softwood fibers. The softwood fibers may bepresent in an amount from about 95% to about 70% by weight.

[0121] Referring to FIG. 2, a method is shown for making throughdriedpaper sheets in accordance with this invention. (For simplicity, thevarious tensioning rolls schematically used to define the several fabricruns are shown but not numbered. It will be appreciated that variationsfrom the apparatus and method illustrated in FIG. 2 may be made withoutdeparting from the scope of the invention). Shown is a twin wire formerhaving a layered papermaking headbox 10 which injects or deposits astream 11 of an aqueous suspension of papermaking fibers onto theforming fabric 13 which serves to support and carry the newly-formed wetweb downstream in the process as the web is partially dewatered to aconsistency of about 10 dry weight percent. Additional dewatering of thewet web may be carried out, such as by vacuum suction, while the wet webis supported by the forming fabric.

[0122] The wet web is then transferred from the forming fabric to atransfer fabric 17 traveling at a slower speed than the forming fabricin order to impart increased stretch into the web. This is commonlyreferred to as a “rush” transfer. Preferably the transfer fabric mayhave a void volume that is equal to or less than that of the formingfabric. The relative speed difference between the two fabrics may befrom 0-60 percent, more specifically from about 10-40 percent. Transferis preferably carried out with the assistance of a vacuum shoe 18 suchthat the forming fabric and the transfer fabric simultaneously convergeand diverge at the leading edge of the vacuum slot.

[0123] The web is then transferred from the transfer fabric to thethrough drying fabric 19 with the aid of a vacuum transfer roll 20 or avacuum transfer shoe, optionally again using a fixed gap transfer aspreviously described. The through drying fabric may be traveling atabout the same speed or a different speed relative to the transferfabric. If desired, the through drying fabric may be run at a slowerspeed to further enhance stretch. Transfer is preferably carried outwith vacuum assistance to ensure deformation of the sheet to conform tothe through drying fabric, thus yielding desired bulk and appearance.

[0124] In one embodiment, the through drying fabric contains high andlong impression knuckles. For example, the through drying fabric mayhave about from about 5 to about 300 impression knuckles per square inchwhich are raised at least about 0.005 inches above the plane of thefabric. During drying, the web is macroscopically arranged to conform tothe surface of the through drying fabric.

[0125] The level of vacuum used for the web transfers may be from about3 to about 15 inches of mercury (75 to about 380 millimeters ofmercury), preferably about 5 inches (125 millimeters) of mercury. Thevacuum shoe (negative pressure) may be supplemented or replaced by theuse of positive pressure from the opposite side of the web to blow theweb onto the next fabric in addition to or as a replacement for suckingit onto the next fabric with vacuum. Also, a vacuum roll or rolls may beused to replace the vacuum shoe(s).

[0126] While supported by the through drying fabric, the web is finaldried to a consistency of about 94 percent or greater by the throughdryer 21 and thereafter transferred to a carrier fabric 22. The driedbasesheet 34 is transported to the reel 24 using carrier fabric 22 andan optional carrier fabric 25. An optional pressurized turning roll 26may be used to facilitate transfer of the web from carrier fabric 22 tofabric 25. Suitable carrier fabrics for this purpose are AlbanyInternational 84M or 94M and Asten 959 or 937, all of which arerelatively smooth fabrics having a fine pattern. Although not shown,reel calendering or subsequent off-line calendering may be used toimprove the smoothness and softness of the basesheet 34.

[0127] In order to improve wet resiliency, the paper web may contain wetresilient fibers, such as high-yield fibers as described above.High-yield fibers include, for instance, thermomechanical pulp, such asbleached chemithermomechanical pulp (BCT&P). The amount of high-yieldpulp fibers present in the sheet may vary depending upon the particularapplication. For instance, the high-yield pulp fibers may be present inan amount of about 5 dry weight percent or greater, or specifically,about 15 dry weight percent or greater, and still more specifically fromabout 15 to about 30%. In other embodiments, the percentage ofhigh-yield fibers in the web may be greater than any of the following:about 30%, about 50%, about 60%, about 70%, and about 90%.

[0128] In one embodiment, the uncreped throughdried web may be formedfrom multiple layers of a fiber furnish. Both strength and softness areachieved through layered webs, such as those produced from stratifiedheadboxes wherein at least one layer delivered by the headbox comprisessoftwood fibers while another layer comprises hardwood or other fibertypes. Layered structures produced by any means known in the art arewithin the scope of the present invention.

[0129] In one embodiment, for instance, a layered or stratified web isformed that contains high-yield pulp fibers in the center. Becausehigh-yield pulp fibers are generally less soft than other paper makingfibers, in some applications it is advantageous to incorporate them into the middle of the paper web, such as by being placed in the center ofa three-layered sheet. The outer layers of the sheet may then be madefrom softwood fibers and/or hardwood fibers.

[0130] In addition to containing high-yield fibers, the paper web mayalso contain a wet strength agent to improve wet resiliency. In fact,the combination of non-compressive drying to mold a three-dimensionalpaper web, coupled with wet strength additives and applying wetresilient fibers produces webs that maintain an unusually high bulk whenwet, even after being compressed.

[0131] “Wet strength agents” are materials used to immobilize the bondsbetween the fibers in the wet state. Any material that when added to apaper web or sheet results in providing the sheet with either a wetgeometric mean tensile strength/dry geometric tensile strength ratio inexcess of 0.1 (the GM wet:dry tensile ratio), or a wet tensilestrength/dry tensile ratio in the cross-direction in excess of 0.1 (theCD wet:dry ratio), will, for purposes of this invention, be termed a wetstrength agent. Typically these materials are termed either as permanentwet strength agents or as “temporary” wet strength agents. For thepurposes of differentiating permanent from temporary wet strength,permanent will be defined as those resins which, when incorporated intopaper or tissue products, will provide a product that retains more than50% of its original wet strength after exposure to water for a period ofat least five minutes. Temporary wet strength agents are those whichshow less than 50% of their original wet strength after being saturatedwith water for five minutes. Both classes of material find applicationin the present invention, though permanent wet strength agents arebelieved to offer advantages when a pad of the present invention is tobe used in a wet state for a prolonged period of time.

[0132] The amount of wet strength agent added to the pulp fibers may beat least about 0.1 dry weight percent, more specifically about 0.2 dryweight percent or greater, and still more specifically from about 0.1 toabout 3 dry weight percent based on the dry weight of the fibers.

[0133] Permanent wet strength agents will provide a more or lesslong-term wet resilience to the structure. In contrast, the temporarywet strength agents would provide structures that had low density andhigh resilience, but would not provide a structure that had long-termresistance to exposure to water. The mechanism by which the wet strengthis generated has little influence on the products of this invention aslong as the essential property of generating water-resistant bonding atthe fiber/fiber bond points is obtained.

[0134] Suitable permanent wet strength agents are typically watersoluble, cationic oligomeric or polymeric resins that are capable ofeither crosslinking with themselves (homocrosslinking) or with thecellulose or other constituent of the wood fiber. The most widely usedmaterials for this purpose are the class of polymer known aspolyamide-polyamine-epichlorohydrin (PAE) type resins. Examples of thesematerials have been sold by Hercules, Inc., Wilmington, Del., as KYMENE557H. Related materials are marketed by Henkel Chemical Co., Charlotte,N.C. and Georgia-Pacific Resins, Inc., Atlanta, Ga.

[0135] Polyamide-epichlorohydrin resins are also useful as bondingresins in this invention. Materials developed by Monsanto and marketedunder the SANTO RES label are base-activated polyamide-epichlorohydrinresins that may be used in the present invention. Although they are notas commonly used in consumer products, polyethylenimine resins are alsosuitable for immobilizing the bond points in the products of thisinvention. Another class of permanent-type wet strength agents isexemplified by the aminoplast resins obtained by reaction offormaldehyde with melamine or urea.

[0136] Suitable temporary wet strength resins include, but are notlimited to, those resins that have been developed by American Cyanamidand are marketed under the name PAREZ 631 NC (now available from CytecIndustries, West Paterson, N.J.). Other temporary wet strength agentsthat could find application in this invention include modified starchessuch as those available from National Starch and marketed as CO-BOND1000. With respect to the classes and the types of wet strength resinslisted, it should be understood that this listing is simply to provideexamples and that this is neither meant to exclude other types of wetstrength resins, nor is it meant to limit the scope of this invention.

[0137] Although wet strength agents as described above find particularadvantage for use in connection with this invention, other types ofbonding agents may also be used to provide the necessary wet resiliency.They may be applied at the wet end of the basesheet manufacturingprocess or applied by spraying or printing, etc. after the basesheet isformed or after it is dried.

[0138] Wet and dry tensile strengths of the absorbent layer can bemeasured with an universal testing machine device such as an Instronapparatus, and using a crosshead speed of 10 inches per minute with a4-inch gage length and a 3-inch jaw width under Tappi standardconditions (samples conditioned 4 hours at 50% relative humidity and 73°F.), The dry tensile strength (taken either in the machine direction,the cross direction, or the geometric mean of the cross and machinedirections) of the absorbent layer may be any of the following: about500 g/3 in or greater, about 1000 g/3 in or greater, about 1500 g/3 inor greater, about 2000 g/3 in or greater, about 2500 g/3 in or greater,and about 3000 g/3 in or greater, such as from about 800 g/3 in to about3000 g/3 in. The wet tensile strength (taken either in the machinedirection, the cross direction, or the geometric mean of the cross andmachine directions) of the absorbent layer may be any of the following:about 200 g/3 in or greater, about 500 g/3 in or greater, about 700 g/3in or greater, about 800 g/3 in or greater, about 1000 g/3 in orgreater, about 1500 g/3 in or greater, and about 2000 g/3 in or greater,such as from about 500 g/3 in to about 2500 g/3 in. Optionally, theabsorbent layer of the present invention may include a multi-ply paperweb, formed of two or more similar or different paper plies. It may benecessary, however, when forming a multi-ply absorbent layer, to providea secure attachment between the plies to ensure good product performanceunder expected conditions. For example, an adhesive such as a hot meltadhesive or other known secure attachment means may be used to securelybind the separate plies together to form the absorbent layer of thescrubbing pad. Exemplary hot melt adhesives may include, withoutlimitation, EVA (ethyl vinyl acetate) hot melts (e.g., copolymers ofEVA), polyolefin hotmelts, polyamide hotmelts, pressure sensitive hotmelts, styrene-isoprene-styrene (SIS) copolymers,styrene-butadiene-styrene (SBS) copolymers; ethylene ethyl acrylatecopolymers (EEA); polyurethane reactive (PUR) hotmelts, and the like. Inone embodiment, poly(alkyloxazoline) hotmelt compounds may be used.Isocyanates, epoxies, and other known adhesives may also be used.Specific examples of adhesives that may be suitable for some embodimentsof the present invention include SUNOCO CP-1500 (an isotacticpolypropylene) of Sunoco Chemicals (Philadelphia, Pa.); Eastman C10,Eastman C18, and Eastman P1010 (an amorphous polypropylene) of EastmanChemical (Longview, Tex.); Findley H1296 and Findley H2525A of ElfAtochem North America (Philadelphia, Pa.); HM-0727, HM-2835Y, and8151-XZP of H. B. Fuller Company (St. Paul, Minn.); and National Starch34-1214 and others adhesives of the National Starch 34 series, made byNational Starch and Chemical Corp. (Berkeley, Calif.).

[0139] When an adhesive compound (including but not limited to hot meltmaterials) is used to join tissue layers or to join a tissue layer to anabrasive web, the adhesive may be bondable to tissue at a temperaturegreater than 110° C., greater than 140° C., or greater than 155° C.,such as from about 110° C. to about 200° C., or from 135° C. to 185° C.Hot melt adhesives generally comprise a polymer that imparts strength, atackifying resin, a plasticizer, and optional components such asantioxidants. The adhesive compound may comprise a plasticizer, such asabout 10% or greater plasticizer by weight, or less than about 30%plasticizer by weight, and more specifically less than about 25%plasticizer by weight. The tackifying resin likewise may likewiseconstitute about 10% by weight or greater of the mass of the adhesive,or less than about 25% by weight or less than about 15% by weight of theadhesive.

[0140] In one embodiment, the adhesive material may be a bicomponentfiber disposed between two adjacent layers such as a sheath-corebicomponent fiber. In addition to conventional bicomponent binderfibers, a fiber comprising two different varieties of polylactic acidmay be used, for polylactic acid may have melting points ranging fromabout 120° C. to 175° C., allowing one form with a high melting point toserve as the core with a lower melting point variety serving as thesheath.

[0141] Latex materials may also serve as the adhesive joining two layersin the product of the present invention. Examples of latex adhesivesinclude latex 8085 from Findley Adhesives. In some embodiments, however,the product is substantially latex free, or may have less than 10 weightpercent latex, more specifically less than 5 weight percent latex, andmost specifically about 2 weight percent latex or less. The latexreferred to for any purpose in the present specification may be anylatex, synthetic latex (e.g., a cationic or anionic latex), or naturallatex or derivatives thereof.

[0142] When hot melt is used as a binder material to join adjacentlayers of material, any known device for applying hot melt may be used,including melt blown devices, ink jet printer heads, spray nozzles, andpressurized orifices. Nozzles or other means may be used to apply theadhesive in a random or non-random pattern, such as a spiral pattern orother patterns. Nozzle diameter may be from about 0.1 mm to 2 mm, morespecifically from about 0.2 mm to about 0.6 mm, or from 0.65 mm to 1.75mm. Alternatively, nozzle diameter may be greater than 0.3 mm or greaterthan 0.6 mm.

[0143] Other systems for applying adhesives to bind layers includesystems for applying a continuous stream of a hot melt adhesive in adistinctive pattern to a substrate. The method includes a gas-directingmechanism for forming a plurality of gas streams arranged to entrain thematerial streams to impart a swirling motion to each of the materialstreams as it moves toward the substrate. Semi-cycloidal patterns of theadhesive on the substrate are achieved while controlling a selectedcross-directional positioning of one or more of the deposited patterns.In addition to semi-cycloidal patterns, any known pattern of hot meltmay be applied as a continuous stream or in discontinuous pulses orsprays to a tissue web or nonwoven layer to form a laminate according tothe present invention. Other exemplary patterns include omega-shapeddeposits, sinusoidal deposits, straight lines, zigzag or saw-toothlines, or top-hat patterns, or combinations thereof. The adhesives mayalso be applied in an open pattern network of filaments of adhesive asis generally known in the art.

[0144] In one embodiment, the absorbent layer of the present inventionmay include a paper web which is somewhat translucent when wet. In thisembodiment, the paper web may have a low degree of opacity such that theabsorbent layer has wet translucence, even in those embodiments whereinthe dry paper web is opaque. If desired, however, the paper web may alsoexhibit some translucence when dry. For example, the wet opacity of thepaper web may be less than about 98% (wet opacity being 100% for anopaque object and 0% for a transparent object). Specifically, the wetopacity of the paper web may be less than about 80%. More specifically,the wet opacity of the paper web may be less than about 60%.

[0145] If desired, the abrasive layer of the web may also betranslucent. Due to the open structure of the abrasive layer, many ofthe open voids, or pores, in the web may extend across the entire depthof the layer, permitting light to pass through the layer unhindered andproviding a degree of translucence to the abrasive layer. For example,more than about 30% of the surface area of the abrasive layer mayinclude pores which extend across the axial depth of the layer. Morespecifically, more than about 50% of the superficial area of theabrasive layer may include pores extending across the layer depth,providing a high degree of translucence to the abrasive layer.Additionally, meltblown abrasive layers may be formed of a translucentpolymer, increasing the translucence of the layer.

[0146] In those embodiments wherein the scrubbing pad is translucent,the user may visually ensure the cleaning effectiveness of the padduring scrubbing. For example, when scrubbing a colored spot, the usermay see visual cues through the translucent pad as to when the spot isremoved.

[0147] The abrasive layer and the absorbent layer may be combined toform the scrubbing pad of the present invention by any suitable method.FIG. 3 illustrates one possible method of combining the layers wherein ameltblown layer 32 is formed directly on the paper web 34 at formingmachine 110. In this embodiment, it may be desired to strengthen thebond between the layers beyond that which is formed when the polymersolidifies on the web. For example, an adhesive could be applied to thepaper web 34 prior to deposition of the meltblown layer 32 on the paperweb 34. The adhesive could then help to adhere the layers of thescrubbing pad together. Alternatively, after forming the meltblown layer32 on the paper web 34, heat and optionally pressure could be applied tothe composite product to fuse the layers together by a thermal bondingprocess. For instance, the composite product could be heated to atemperature to soften the fibers of the meltblown layer so as to developa degree of penetration of a portion of the polymer into the facingsurface of the paper web to create a strong, durable bond between thelayers.

[0148] In an embodiment such as that illustrated in FIG. 3, it may bedesirable to maintain an elevated temperature of the meltblown as ithits the tissue such that the meltblown material may bond with thefibers of the tissue layer. Without wishing to be bound by theory, it isbelieved that for good adhesion of the meltblown layer to the tissueduring use, i.e., when the laminate is wet and subjected to scrubbingaction, a portion of the meltblown material may be entangled with thefibers of the tissue web or may have penetrated within the porous matrixof the tissue web enough to prevent delamination of the meltblown layerfrom the tissue when the tissue is wetted. Achieving such results may bedone through the use of heated air to carry the meltblown from themeltblown spinnerets to the tissue web, and/or the use of vacuum beneaththe tissue web to pull a portion of the viscous meltblown material intothe porous matrix of the tissue web. For example, vacuum may be appliedin the formation zone to help pull the polymer fibers into the web forbetter bonding and possible entanglement with the cellulosic fibers.When vacuum is used, however, care should be taken to prevent excessiveairflow in the vicinity of the tissue that could solidify the meltblownfibers prior to contacting the tissue. Narrow vacuum boxes, controlledair flow rates, pulsed vacuum, and other means, optionally coupled withradiative heating or other means of temperature control of the materialsor fluids (e.g., air), may be used by those skilled in the art tooptimize the bonding between the abrasive layer and the absorbent layer.

[0149] In one embodiment, the cellulosic web may be preheated or heatedas the polymeric fibers are deposited thereon (whether by meltblown orspunbond formation directly on the cellulosic web, or by joining apreviously formed layer of polymeric fibers to the cellulosic web). Forexample, an IR lamp or other heating source may be used to heat thecellulosic web in the vicinity where polymeric fibers contact thecellulosic web. By heating the surface of the cellulosic web, betterbonding between the cellulosic web and the polymeric fibers may beachieved, especially when the fibers are newly formed, cooling meltblownfibers. A combination of heating and suction beneath the cellulosic webmay be helpful, and either or both operations may further be combinedwith mechanical pressing (e.g., spot bonding, roll pressing, stamping,etc.) to further bond polymeric fibers to the cellulosic web.

[0150] Alternatively, the paper web and the abrasive layer of thescrubbing pad may be separately formed, and then attached later, afterformation. For example, as illustrated in FIG. 4, paper web 34 andmeltblown web 32 may be guided together with guide rolls 102 and 104 andbrought in contact between roll 100 and roll 80.

[0151] When a thermoplastic-containing abrasive layer has beenpreviously formed and is no longer hot enough to readily bond to theabsorbent layer, heat may be applied to cause joining of the abrasivelayer with the absorbent layer as the two are brought into contact orafter the two are brought into contact. For example, the absorbent layermay be preheated sufficiently to cause partial fusion of the abrasivelayer as it touches the paper web, optionally with the assistance ofmechanical compression. Alternatively, heat may be applied to the tissueand/or the abrasive layer after the two have been brought into contactto cause at least partial fusion of the meltblown layer with theabsorbent layer. The heat may be applied conductively, such as bycontacting the tissue layer against a heated surface that heats thetissue sufficiently to cause fusion of parts of the abrasive layer incontact with the tissue, preferably without heating the polymeric layertoo much. Radiative heating, radio frequency heating (e.g., microwaveheating), inductive heating, convective heating with heated air, steam,or other fluids, and the like may be applied to heat the tissue layerand the polymeric layer while in contact with each other, or toindependently heat either layer prior to being joined to the other.

[0152] Ultrasonic bonding and pattern bonding may also be applied. Forexample, a rotary horn activated by ultrasonic energy may compress partsof the abrasive layer against the tissue web and cause fusion of partsof the polymeric layer due to a welding effect driven by the ultrasound.Likewise, a patterned heated plate or drum may compress portions of theabrasive layer in contact with the tissue to cause the compressedportions such that good attachment of the compressed portions to thetissue web is achieved.

[0153] In an alternative embodiment, as shown in FIG. 5, the layers ofthe present invention may be brought together after formation, and anadhesive 82 may be applied to one or both layers of the pad prior tocontact which may bond the layers of the pad together. In thisembodiment, the layers may be attached through utilization of theadhesive alone, or optionally, heat and/or pressure may also be appliedafter the layers are brought together, to further enhance the bondbetween the layers. An adhesive may be applied to one or both of thelayers of the scrubbing pad by any method. For example, in addition to aspray method, as illustrated in FIG. 5, an adhesive may be appliedthrough any known, printing, coating, or other suitable transfer method.In addition, the adhesive may be any suitable adhesive which may firmlybond the layers of the pad together. The basis weight of the adhesivemay be about 5 gsm or greater, such as from about 10 gsm to about 50gsm, more specifically about 15 gsm to about 40 gsm. Alternatively, thebasis weight of the added adhesive may be less than about 5 gsm.

[0154] The most suitable method of joining the layers of the scrubbingpad together may depend at least in part on the textures of the layers.As previously discussed, the meltblown layer and/or the paper web may beformed on relatively smooth forming surfaces and therefore displaylittle three dimensional surface texture, or alternatively, one or bothof the layers may be formed on highly texturized surfaces. For instance,FIG. 7 illustrates the cross-section of a scrubbing pad 30 formed of anabrasive layer 32 joined to a paper web 34, both of which are haverelatively smooth surface textures. In such an embodiment, any of anumber of methods could be used to join the layers together includingmethods involving adhesives, heat, pressure, or any combination thereof.

[0155] In an alternative embodiment, one or both of the layers mayexhibit a high degree of surface texture. For example, as illustrated inFIG. 8, the meltblown layer 32 may be a highly textured meltblown layerand the paper web 34 may be relatively flat. In such an embodiment, aspot bonding method may be preferred to firmly bond the layers at thosepoints where the meltblown layer 32 and the paper web 34 contact whilemaintaining the texture of the meltblown layer 32. Any of a variety ofknown spot bonding methods may be used, including those methodsinvolving various adhesives and/or heat, without subjecting thecomposite structure to excessive pressure which could damage the textureof the meltblown layer 34. Of course, the scrubbing pad may optionallybe formed of a highly textured paper web bonded to a relatively flatabrasive layer. Alternatively, both of the layers may be highlytextured, and may have the same or different texturing patterns.

[0156] A variety of alternative methods may also be utilized to join twoor more tissue layers, or a tissue layer to an abrasive layer. Thesemethods includes, but are not limited to:

[0157] Adding non-tacky binder fibers between two adjacent layers, andsubsequently applying heat (e.g., infrared radiation, heated air,contact with heated surfaces, inductive heating, microwave radiation,and the like) to cause at least partial fusion of the binder fibers tojoin the adjacent layers. The layers may be substantially uncompressedor may be subject to mechanical compression during or after heatingwhile the binder fibers are still hot enough to be capable of bonding.When mechanical compression is used to facilitate bonding, the appliedmechanical loads less than any of the following: 100 kPa, 50 kPa, 25kPa, 10 kPa, 5 kPa, 1 kPa, or loads between about 1 kPa and 20 kPa, orbetween 10 kPa and 50 kPa).

[0158] Applying tacky hot melt material to one or more layers prior tocontact with an adjacent layer. The hot melt may be in the form ofmeltblown fibers entrained in hot air to prevent premature quenching, orsufficiently heated hot melt material that may remain tacky after itcontacts the layer to which it is applied, after which a second layer isbrought into contact with the hot melt material on the first layer tocause bonding of the two layers. One possible method for laminating twolayers includes through-injecting meltblown fibers from a meltblown headbetween two layers supported on opposing suction rolls which do not jointhe layers together, followed by a calendar roll or embossing roll whichdoes press the layers together to cause bonding.

[0159] Extrusion of a thermoplastic or tacky polymeric foam between thetwo layers, such as a molten foam precursor with blowing agents thatexpand after extrusion to create a porous structure in the foam. Thefoam may be open celled foam with small enough pore sizes (e.g., lessthan 1 mm, such as from about 10 microns to 50 microns) to causegeneration of foam when a wipe comprising the foam is used with soapywater or water containing other foamable cleaning agents, whereinsqueezing the product while wet with cleaning solution generates foam asthe solution is forced through the absorbent layer, as is often casewhen using conventional sponges. However, only a thin layer of foam maybe needed to achieve both the binding effect and the foam-generatingeffect when used with certain cleaning solutions. The foam layer mayhave a thickness of less than 8 mm, such as from about 0.5 mm to 6 mm,or from 1 mm to 3 mm, and may have a basis weight of less than 10 gsm orless than 5 gsm, though higher basis weights may be employed, such as 10gsm or greater, 20 gsm or greater, 30 gsm or greater, or about 40 gsm orgreater, with exemplary ranges of from about 15 gsm to about 60 gsm orfrom about 20 gsm to about 60 gsm. In one embodiment, a foam layer maybe on both sides of the absorbent layer, i.e. between the two primarylayers of the scrubbing pad and on the outer surface of the absorbentlayer.

[0160] Mechanical bonding may also be used, including needling orcrimping of adjacent layers to create bonding by mechanical entanglementof fibers. However, some degree of adhesive bonding may still be neededfor best results.

[0161] Applying binder materials other than thermoplastic binders tojoin the adjacent layers. Such binder materials may include pressuresensitive adhesives; curable adhesives such as glues; salt sensitivebinders that are effective in the presence of a salt-containingsolution.

[0162] The composite scrubbing pad of the present invention will includeboth an abrasive layer and an absorbent layer which are usually attacheddirectly to each other, though in certain embodiments an additionallayer may be included between the two primary layers. FIG. 7 illustratesthe cross-section of one embodiment of a scrubbing pad 30 including anabrasive layer 3 and an absorbent layer 34, both of which haverelatively smooth surface textures. In such an embodiment, any of anumber of methods may be used to join the layers together includingmethods involving adhesives, heat pressure, or any combination thereof.

[0163] In an alternative embodiment, one or both of the layers mayexhibit a high degree of surface texture. For example, as illustrated inFIG. 8, the abrasive layer 32 may be highly textured at the scrubbingsurface and the absorbent layer 34 may be relatively flat. In such anembodiment, the method of joining the two layers is limited only in thatit should not destroy the surface texture of the layer.

[0164]FIG. 9 illustrates another embodiment of the scrubbing pad whereinboth the absorbent layer 34 and the abrasive layer 32 display a highdegree of three-dimensional texture. In the embodiment illustrated inFIG. 9, both layers have the same, nested texturing pattern.Alternatively, the layers may have different texturing patterns. As withthe other embodiments, the only limitation in the method of joining thetwo layers together is that the desired surface texture of a layer notbe destroyed in the attachment method. For example, when the two layersdisplay different, overlapping texturing patterns, a spot bonding methodmay be preferred.

[0165] In an embodiment such as that illustrated in FIG. 9, the surfacetexture in one of the layers may be formed when the two layers areattached together. For example, the absorbent layer 34 may be a highlytextured cellulosic fibrous web, such as an uncreped through dried paperweb, and the abrasive layer 32 may be formed on or bonded to theabsorbent layer and may conform to the texturing pattern of theabsorbent layer at the time the two layers are combined. For instance,heat may be applied to the composite article as a part of the bondingprocess. This may cause the abrasive layer to soften and take on thetexturing pattern of the absorbent layer, and the abrasive layer maycontinue to display the same texture pattern as the absorbent layerafter the layers are attached together.

[0166] Increasing the surface texture of the abrasive layer in such amanner may increase the overall abrasiveness of the composite product.Thus, a synergy may exist between the two layers, and the overallabrasiveness of the composite scrubbing article at the abrasive surfacemay be greater than the abrasiveness of either layer prior to theattachment.

[0167] Moreover, in those embodiments wherein the absorbent layer of theweb can exhibit a high degree of wet resilience, the added texture ofthe abrasive layer can endure, even after the scrubbing article has beensaturated with water or some other cleaning fluid.

[0168] The composite scrubbing pad may exhibit a synergy between thelayers in other ways as well. For example, the fibers of the two layersmay be physically entangled or fused together in the attachment process,such that there is a fairly strong bond between the layers. In such anembodiment, the tensile strength of the composite product may be greaterthan the sum of the tensile strengths of the two layers prior toattachment, or, alternatively, greater than the tensile strengthmeasured when the two layers are coextensively disposed adjacent to oneanother but not bonded together, and tested together for combinedtensile strength.

[0169] The composite scrubbing pads of the present invention may exhibitdesired cleaning characteristics, such as good abrasiveness and wetresiliency, for example while requiring less raw material and havinggood flexibility for easy handling. For example, in one embodiment, thescrubbing pads of the present invention may have an overall basis weightof less than 150 gsm. The scrubbing pads of the present invention mayalso be less than about 7 mm in thickness. More particularly, thescrubbing pads may be less than about 4 mm in thickness. The abrasivelayer may have a thickness of about 0.5 mm or greater, as measured withthe equipment used in the Thickness Variation test, or the thickness maybe any of the following values: about 1 mm or greater, about 2 mm orgreater, about 3 mm or greater, about 4 mm or greater, about 5 mm orgreater, such as from about 0.5 mm to 10 mm, or from about 1 mm to 5 mm.Alternatively, the thickness of the abrasive layer can be less than 3mm.

[0170] Additional layers may also be included in the scrubbing pad ofthe present invention, if desired. For instance, the scrubbing pad ofthe present invention may include two abrasive layers on oppositesurfaces of the pad, both attached to one or more absorbent layers whichare sandwiched in the middle of the pad.

[0171] In one embodiment of the present invention, a barrier layerformed of a barrier material or sizing agent may be included in or oneither side of the absorbent layer. This may be useful when smallquantities of a cleaning compound are used (e.g., a furniture polish, awindow washer, or a harsh agent such as an oven cleaning agent), whereinwetting the entire pad is undesirable. For example, a barrier layer maybe between the absorbent layer and the abrasive layer, or,alternatively, may be on the outer surface of the absorbent layer. Inone embodiment, the barrier material may be removable. For example, inone embodiment of the present invention a barrier layer may include awater impervious barrier material on the outer surface of the absorbentlayer that may allow the hand to remain dry during use.

[0172] The barrier material, in one embodiment, may be a hydrophobicfilm. It should be understood, however, that any suitable waterimpermeable material may be used. For instance, suitable moisturebarrier materials include films, wovens, nonwovens, laminates, or thelike. The barrier material may be a liquid impermeable web or sheet ofplastic film such as polyethylene, polypropylene, polyvinylchloride orsimilar material. Moreover, the barrier material may occupy only aportion of the surface area of the paper web or may substantially coveran entire surface of the paper web.

[0173] In addition to the paper web and the abrasive layer, thescrubbing pad of the present invention may also contain additionalmaterials within either layer as well as additional functional layers orcomponents. For example, a portion of the pad may provide a soap,detergent, waxes or polishing agents such as furniture polish, metalcleaners, leather and vinyl cleaning or restoration agents, stainremovers for rubbing on clothing, laundry pre-treatment solutions,enzymatic solutions for improved cleaning or fabric conditioning, odorcontrol agents such as the active ingredients of Fabreze® odor removingcompound (Procter and Gamble, Cincinnati, Ohio), water proofingcompounds, shoe polish, dyes, glass cleaner, antimicrobial compounds,wound care agents, lotions and emollients, and the like. Other possibleadditives that may be added to the scrubbing pad include bufferingagents, antimicrobials, skin wellness agents such as lotions,medications (i.e. anti-acne medications), or hydrophobic skin barriers,odor control agents, surfactants, mineral oil, glycerin and the like.

[0174] The active ingredients may be present in a solution on the wipeas it is packaged or in a solution that is added to the wipe prior touse. Active ingredients can also be present as a dry powder attached tofibers in the wipe, or as a dry compound impregnated in the fibers or invoid spaces between the fibers of the wipe, or encapsulated inwater-soluble capsules, encapsulated in waxy or lipid-rich shells topermit escape upon mechanical compression or shear, or in a containerattached to or cooperatively associated with the wipe that may be openedduring use or prior to use.

[0175] Application of the additives may be by any suitable method, suchas:

[0176] Direct addition to a fibrous slurry prior to formation of thepaper web.

[0177] A spray applied to a layer or the composite pad. For example,spray nozzles may be mounted over the moving paper web or the meltblownweb to apply a desired dose of a solution to the layer that may be moistor substantially dry.

[0178] Printing onto the web, such as by offset printing, gravureprinting, flexographic printing, ink jet printing, digital printing ofany kind, and the like.

[0179] Coating onto one or both surfaces of a layer, such as bladecoating, air knife coating, short dwell coating, cast coating, and thelike.

[0180] Extrusion from a die head of an agent in the form of a solution,a dispersion or emulsion, or a viscous mixture such as one comprising awax, softener, debonder, oil, polysiloxane compound or other siliconeagent, an emollient, a lotion, an ink, or other additive.

[0181] Application to individualized fibers. For example, prior todeposit on the forming surface, the meltblown fibers may be entrained inan air stream combined with an aerosol or spray of the compound to treatindividual fibers prior to incorporation into the meltblown layer.

[0182] Impregnation of the wet or dry paper web with a solution orslurry, wherein the compound penetrates a significant distance into thethickness of the web, such as more than 20% of the thickness of the web,more specifically at least about 30% and most specifically at leastabout 70% of the thickness of the web, including completely penetratingthe web throughout the full extent of its thickness.

[0183] Foam application of an additive to a layer (e.g., foamfinishing), either for topical application or for impregnation of theadditive into the paper web under the influence of a pressuredifferential (e.g., vacuum-assisted impregnation of the foam).

[0184] Padding of a chemical agent in solution into an existing fibrousweb.

[0185] Roller fluid feeding of the additive for application to the web.

[0186] Application of the agent by spray or other means to a moving beltor fabric which in turn contacts the layer to apply the chemical to thelayer.

[0187] The application level of an additive may generally be from about0.1 weight % to about 10 weight % solids relative to the dry mass of thelayer to which it is applied. More specifically, the application levelmay be from about 0.1% to about 4%, or from about 0.2% to about 2%.Higher and lower application levels are also within the scope of thepresent invention. In some embodiments, for example, application levelsof from 5% to 50% or higher may be considered.

[0188] Printing, coating, spraying, or otherwise transferring a chemicalagent or compound on one or more sides of the pad, or of any layer ormaterial in the pad may be done uniformly or heterogeneously, as in apattern, using any known agent or compound (e.g., a silicone agent, aquaternary ammonium compound, an emollient, a skin-wellness agent suchas aloe vera extract, an antimicrobial agent such as citric acid, anodor-control agent, a pH control agent, a sizing agent; a polysaccharidederivative, a wet strength agent, a dye, a fragrance, and the like). Anyknown method may be used for application of such additives.

[0189] In one embodiment, the scrubbing pad may be provided and thedesired additive compound may be held in a separate container ordispenser. In this embodiment, the additive may be applied to the pad bythe consumer in the desired amount at the time of use.

[0190] The layers of the scrubbing pad of the present invention may becombined to form a product of any desired size or shape and suited forany particular purpose. For example, FIG. 6 illustrates one embodimentof the present invention wherein a meltblown layer 32 substantiallycovers the surface of a paper web 34 to form a rectangular scrubbing padsuch as may be held in the hand during use. In such an embodiment, thescrubbing pad may be reversed to provide both abrasive and non-abrasivetype cleaning.

[0191] Alternatively, the meltblown layer may only partially cover thesurface of the paper web, creating a single scrubbing surface on ascrubbing pad which may have both a coarse abrasive region and a smooth,absorbent region. Thus, the user may control the abrasiveness of thecleaning action during cleaning by, for instance, adjusting the angle ofthe pad or the region of the pad to which pressure is applied and mayhave different levels of scrubbing action on the same side of a singlescrubbing pad.

[0192] The scrubbing pads of the present invention may be provided inany shape or orientation. For example, the pads may be square, circular,rectangular, or the like. They may be formed into mitts, such ashand-shaped mitts for scrubbing with the hand or foot-shaped covers forthe feet. The pads may be packaged and sold in either a wet or dry form,and may optionally be shaped to be attached to a handle or gripper toform a convenient cleaning tool such as a wiper with a squeegee, a mop,a toilet cleaning tool, a dishwashing wipe, a scouring pad, a scrubbingtool for cleaning metal, ceramic, or concrete surfaces, a polishing orsanding tool, and the like.

[0193] For example, one embodiment of the invention, as illustrated inFIG. 10, shows the scrubbing pad of the present invention 30 shaped soas to be attachable to a base 220 of a rigid gripping device. The base220 is attached to a handle 210 shaped to be comfortably held by a user,such as is found on a mop or smaller, hand-held scrubbing device. Thescrubbing pad 30 may be held onto the base 220 by any method that canfirmly hold the pad, yet, in one embodiment, can release the pad forreplacement quickly and easily. For example, the pad 30 may be held ontobase 220 at gripping slots 225. In another embodiment, the scrubbing pad30 may be permanently attached to the base 220, and the entire cleaningtool 10 can be disposable.

[0194] The cleaning tool of the present invention can be used to cleanor scrub many different surfaces, and can be designed for a specificuse. For example, the cleaning tool can have a handle including a longwand and be used to clean floors, walls, ceilings, ceiling fans, lightfixtures, windows and the like. In certain embodiments, such as when thecleaning tool is used to clean windows, for example, the cleaning toolcan have a squeegee attachment, such as a rubber material squeegeeattached to a surface as is generally known in the art. In otherembodiments, the abrasive layer on the cleaning tool can be used forsanding or polishing a surface to be cleaned.

Test Methods

[0195] “Gurley Stiffness” refers to measurements of the stiffness of aweb made with a Gurley® Bending Resistance Tester, Model 4171-D(Precision Instruments, Troy, N.Y.). Tests are made with samplesconditioned for at least four hours under Tappi conditions (50% relativehumidity, 23° C). A suitable method for determining Gurley stiffnessvalues follows that set forth in TAPPI Standard Test T 543 OM-94, butmodified to use sample lengths of 1.5 inches instead of 2 inches, andsample widths of 1.0 inches instead of 2 inches. Using a 1-inch widesample that is 1.5 inches long, the formula to convert the Gurleyreading to Gurley Stiffness with units of milligrams is:Stiffness=Gurley reading*11.1 mg*(inches from center/1 inch)*(weight/5g).

[0196] Thus, a Gurley reading of 8 taken when a 25 g weight was used 2inches from center would be converted to a stiffness of 8*11.1 mg*2 *(25g/5 g)=888 mg.

[0197] The abrasive layers of the present invention and/or the laminatedproducts of the present invention may have a Gurley stiffness of about2500 mg or less, specifically about 1500 mg or less, more specificallyabout 800 mg or less, more specifically still about 400 mg or less, andmost specifically about 200 mg or less, such as from about 40 mg to 350mg or from about 80 mg to about 400 mg. These stiffness values may bethe maximum value obtainable for measurements in any direction of theweb or product (the maximum stiffness), or in the machine direction orcross-direction (MD or CD stiffness, respectively).

[0198] “Thickness Variation” refers to the nonuniformity of thethickness of an abrasive layer. The measurement involves taking spacedapart measurements of sample thickness with a TMI Model 49-62 PrecisionMicrometer (Testing Machines, Inc., Amityville, N.Y.) having a 0.63-inchdiameter foot that applies a pressure of 7.3 psi (50 kPa). Testing isdone after the instrument has warmed up for one hour and is done underTappi standard conditions. Strips of the material to be tested aremeasured at spots on one-inch centers to provide multiple measurementsper strip. At least 3 strips of material are used, and at least 9readings per strip are taken. The thickness variation is the standarddeviation of the thickness results, reported in millimeters.

[0199] “Wet Opacity” and “Dry Opacity” refer to measurements of theoptical opacity of a sample in the dry or wet state, respectively, usinga Technibrite® Micro TB-1C device (Technidyne Corp., New Albany, Ind.),according to manufacturer directions for ISO opacity, with testing donefor samples with the abrasive layer up. Testing is done under Tappistandard conditions. Wet Opacity is the measurement of opacity of asample that has been wetted by immersing and soaking the sample for oneminute deionized water at 23° C. The sample is then removed from thewater, holding it by one corner to allow drain excess water to drain forthree seconds. The sample is then placed on dry blotter paper for 20seconds, then turned over and placed on another dry blotter and allowedto sit for another 20 seconds, then immediately tested for opacity.

[0200] In some embodiments, the articles of the present invention have arelatively low Wet Opacity, such that the user can observe the presenceof spots or other objects through the wetted article during cleaning.Conventional sponges and other cleaning articles tend to besubstantially opaque, but the translucent nature of the articles in someembodiments of the present invention may be of use in some cleaningsituations. Thus, the articles of the present invention may have a WetOpacity less than about any of the following: 95%, 90%, 80%, 70%, 60%,50%, and 40%, with exemplary ranges of from 30% to 95%, or from 50% to90%, or from 40% to 80%. Dry Opacity may be greater than 96%, such asabout 100%, or may be less than 96%, such as from 80% to about 95%, orfrom 50% to 90%, or from 40% to 85%. In one embodiment, the differencebetween dry opacity and wet opacity of the article can be at least about10%.

[0201] “Overall Surface Depth”. A three-dimensional basesheet or web isa sheet with significant variation in surface elevation due to theintrinsic structure of the sheet itself. As used herein, this elevationdifference is expressed as the “Overall Surface Depth.” The basesheetsuseful for this invention may possess three-dimensionality and may havean Overall Surface Depth of about 0.1 mm. or greater, more specificallyabout 0.3 mm. or greater, still more specifically about 0.4 mm. orgreater, still more specifically about 0.5 mm. or greater, and stillmore specifically from about 0.4 to about 0.8 mm. However, products madesubstantially flat tissue are within the scope of certain embodiments ofthe present invention as well.

[0202] The three-dimensional structure of a largely planar sheet may bedescribed in terms of its surface topography. Rather than presenting anearly flat surface, as is typical of conventional paper,three-dimensional sheets useful in producing the present invention havesignificant topographical structures that, in one embodiment, may derivein part from the use of sculptured through-drying fabrics such as thosetaught by Chiu et al. in U.S. Pat. No. 5,429,686, previouslyincorporated by reference. The resulting basesheet surface topographytypically comprises a regular repeating unit cell that is typically aparallelogram with sides between about 2 and 20 mm in length. Forwetlaid materials, these three-dimensional basesheet structures becreated by molding the moist sheet or may be created prior to drying,rather than by creping or embossing or other operations after the sheethas been dried. In this manner, the three-dimensional basesheetstructure is more likely to be well retained upon wetting, helping toprovide high wet resiliency and to promote good in-plane permeability.For air-laid basesheets, the structure may be imparted by thermalembossing of a fibrous mat with binder fibers that are activated byheat. For example, an air-laid fibrous mat containing thermoplastic orhot melt binder fibers may be heated and then embossed before thestructure cools to permanently give the sheet a three-dimensionalstructure.

[0203] In addition to the regular geometrical structure imparted by thesculptured fabrics and other fabrics used in creating a basesheet,additional fine structure, with an in-plane length scale less than about1 mm, may be present in the basesheet. Such a fine structure may stemfrom microfolds created during differential velocity transfer of the webfrom one fabric or wire to another prior to drying. Some of thematerials of the present invention, for example, appear to have finestructure with a fine surface depth of 0.1 mm or greater, and sometimes0.2 mm or greater, when height profiles are measured using a commercialmoiré interferometer system. These fine peaks have a typical half-widthless than 1 mm. The fine structure from differential velocity transferand other treatments may be useful in providing additional softness,flexibility, and bulk. Measurement of the surface structures isdescribed below.

[0204] An especially suitable method for measurement of Overall SurfaceDepth is moiré interferometry, which permits accurate measurementwithout deformation of the surface. For reference to the materials ofthe present invention, surface topography should be measured using acomputer-controlled white-light field-shifted moiré interferometer withabout a 38 mm field of view. The principles of a useful implementationof such a system are described in Bieman et al. (L. Bieman, K. Harding,and A. Boehnlein, “Absolute Measurement Using Field-Shifted Moir{acuteover (e,)},” SPIE Optical Conference Proceedings, Vol. 1614, pp.259-264, 1991). A suitable commercial instrument for moiréinterferometry is the CADEYES® interferometer produced by Medar, Inc.(Farmington Hills, Mich.), constructed for a nominal 35-mm field ofview, but with an actual 38-mm field-of-view (a field of view within therange of 37 to 39.5 mm is adequate). The CADEYES® system uses whitelight which is projected through a grid to project fine black lines ontothe sample surface. The surface is viewed through a similar grid,creating moire fringes that are viewed by a CCD camera. Suitable lensesand a stepper motor adjust the optical configuration for field shifting(a technique described below). A video processor sends captured fringeimages to a PC computer for processing, allowing details of surfaceheight to be back calculated from the fringe patterns viewed by thevideo camera.

[0205] In the CADEYES moiré interferometry system, each pixel in the CCDvideo image is said to belong to a moiré fringe that is associated witha particular height range. The method of field-shifting, as described byBieman et al. (L. Bieman, K. Harding, and A. Boehnlein, “AbsoluteMeasurement Using Field-Shifted Moiré,” SPIE Optical ConferenceProceedings, Vol. 1614, pp. 259-264, 1991) and as originally patented byBoehnlein (U.S. Pat. No. 5,069,548, herein incorporated by reference),is used to identify the fringe number for each point in the video image(indicating which fringe a point belongs to). The fringe number isneeded to determine the absolute height at the measurement pointrelative to a reference plane. A field-shifting technique (sometimestermed phase-shifting in the art) is also used for sub-fringe analysis(accurate determination of the height of the measurement point withinthe height range occupied by its fringe). These field-shifting methodscoupled with a camera-based interferometry approach allows accurate andrapid absolute height measurement, permitting measurement to be made inspite of possible height discontinuities in the surface. The techniqueallows absolute height of each of the roughly 250,000 discrete points(pixels) on the sample surface to be obtained, if suitable optics, videohardware, data acquisition equipment, and software are used thatincorporates the principles of moiré interferometry with field shifting.Each point measured has a resolution of approximately 1.5 microns in itsheight measurement.

[0206] The computerized interferometer system is used to acquiretopographical data and then to generate a grayscale image of thetopographical data, said image to be hereinafter called “the heightmap.” The height map is displayed on a computer monitor, typically in256 shades of gray and is quantitatively based on the topographical dataobtained for the sample being measured. The resulting height map for the38-mm square measurement area should contain approximately 250,000 datapoints corresponding to approximately 500 pixels in both the horizontaland vertical directions of the displayed height map. The pixeldimensions of the height map are based on a 512×512 CCD camera whichprovides images of moiré patterns on the sample which can be analyzed bycomputer software. Each pixel in the height map represents a heightmeasurement at the corresponding x- and y-location on the sample. In therecommended system, each pixel has a width of approximately 70 microns,i.e. represents a region on the sample surface about 70 microns long inboth orthogonal in-plane directions). This level of resolution preventssingle fibers projecting above the surface from having a significanteffect on the surface height measurement. The z-direction heightmeasurement must have a nominal accuracy of less than 2 microns and az-direction range of at least 1.5 mm. (For further background on themeasurement method, see the CADEYES Product Guide, Integral Vision(formerly Medar, Inc.), Farmington Hills, Mich., 1994, or other CADEYESmanuals and publications of Medar, Inc.)

[0207] The CADEYES system can measure up to 8 moiré fringes, with eachfringe being divided into 256 depth counts (sub-fringe heightincrements, the smallest resolvable height difference). There will be2048 height counts over the measurement range. This determines the totalz-direction range, which is approximately 3 mm in the 38-mmfield-of-view instrument. If the height variation in the field of viewcovers more than eight fringes, a wrap-around effect occurs, in whichthe ninth fringe is labeled as if it were the first fringe and the tenthfringe is labeled as the second, etc. In other words, the measuredheight will be shifted by 2048 depth counts. Accurate measurement islimited to the main field of 8 fringes.

[0208] The moiré interferometer system, once installed and factorycalibrated to provide the accuracy and z-direction range stated above,can provide accurate topographical data for materials such as papertowels. (Those skilled in the art may confirm the accuracy of factorycalibration by performing measurements on surfaces with knowndimensions.) Tests are performed in a room under Tappi conditions (73°F., 50% relative humidity). The sample must be placed flat on a surfacelying aligned or nearly aligned with the measurement plane of theinstrument and should be at such a height that both the lowest andhighest regions of interest are within the measurement region of theinstrument.

[0209] Once properly placed, data acquisition is initiated usingCADEYES® PC software and a height map of 250,000 data points is acquiredand displayed, typically within 30 seconds from the time dataacquisition was initiated. (Using the CADEYES® system, the “contrastthreshold level” for noise rejection is set to 1, providing some noiserejection without excessive rejection of data points.) Data reductionand display are achieved using CADEYES® software for PCs, whichincorporates a customizable interface based on Microsoft Visual BasicProfessional for Windows (version 3.0), running under Windows 3.1. TheVisual Basic interface allows users to add custom analysis tools.

[0210] The height map of the topographical data may then be used bythose skilled in the art to identify characteristic unit cell structures(in the case of structures created by fabric patterns; these aretypically parallelograms arranged like tiles to cover a largertwo-dimensional area) and to measure the typical peak to valley depth ofsuch structures. A simple method of doing this is to extracttwo-dimensional height profiles from lines drawn on the topographicalheight map which pass through the highest and lowest areas of the unitcells. These height profiles may then be analyzed for the peak to valleydistance, if the profiles are taken from a sheet or portion of the sheetthat was lying relatively flat when measured. To eliminate the effect ofoccasional optical noise and possible outliers, the highest 10% and thelowest 10% of the profile should be excluded, and the height range ofthe remaining points is taken as the surface depth. Technically, theprocedure requires calculating the variable which we term “P10,” definedat the height difference between the 10% and 90% material lines, withthe concept of material lines being well known in the art, as explainedby L. Mummery, in Surface Texture Analysis: The Handbook, HommelwerkeGmbH, Mühlhausen, Germany, 1990. In this approach, which will beillustrated with respect to FIG. 7, the surface 31 is viewed as atransition from air 32 to material 33. For a given profile 30, takenfrom a flat-lying sheet, the greatest height at which the surfacebegins—the height of the highest peak—is the elevation of the “0%reference line” 34 or the “0% material line,” meaning that 0% of thelength of the horizontal line at that height is occupied by material.Along the horizontal line passing through the lowest point of theprofile, 100% of the line is occupied by material, making that line the“100% material line” 35. In between the 0% and 100% material lines(between the maximum and minimum points of the profile), the fraction ofhorizontal line length occupied by material will increase monotonicallyas the line elevation is decreased. The material ratio curve 36 givesthe relationship between material fraction along a horizontal linepassing through the profile and the height of the line. The materialratio curve is also the cumulative height distribution of a profile. (Amore accurate term might be “material fraction curve.”)

[0211] Once the material ratio curve is established, one may use it todefine a characteristic peak height of the profile. The P10 “typicalpeak-to-valley height” parameter is defined as the difference 37 betweenthe heights of the 10% material line 38 and the 90% material line 39.This parameter is relatively robust in that outliers or unusualexcursions from the typical profile structure have little influence onthe P10 height. The units of P10 are mm. The Overall Surface Depth of amaterial is reported as the P10 surface depth value for profile linesencompassing the height extremes of the typical unit cell of thatsurface. “Fine surface depth” is the P10 value for a profile taken alonga plateau region of the surface which is relatively uniform in heightrelative to profiles encompassing a maxima and minima of the unit cells.Measurements are reported for the most textured side of the basesheetsof the present invention, which is typically the side that was incontact with the through-drying fabric when airflow is toward thethrough-dryer.

[0212] Overall Surface Depth is intended to examine the topographyproduced in the tissue web, especially those features created in thesheet prior to and during drying processes, but is intended to exclude“artificially” created large-scale topography from dry convertingoperations such as embossing, perforating, pleating, etc. Therefore, theprofiles examined should be taken from unembossed regions if the tissueweb has been embossed, or should be measured on an unembossed tissueweb. Overall Surface Depth measurements should exclude large-scalestructures such as pleats or folds which do not reflect thethree-dimensional nature of the original basesheet itself. It isrecognized that sheet topography may be reduced by calendering and otheroperations which affect the entire basesheet. Overall Surface Depthmeasurement may be appropriately performed on a calendered basesheet.

[0213] The CADEYES® system with a 38-mm field of view may also be usedto measure the height of material on an abrasive layer relative to theunderlying tissue web, when there are openings in the abrasive layerthat permit optical access to and measurement of the surface of thetissue web. When the abrasive layer comprises a translucent material,obtaining good optical measurements of the surface topography mayrequire application of white spray paint to the surface to increase theopacity of the surface being measured.

[0214] Test for Abrasive Index

[0215] As used herein, the “Abrasiveness Index” is a measure of theability of an abrasive layer to abrade away material from a block of afoam that is moved over the surface of the abrasive layer in aprescribed manner under a fixed load. The Abrasiveness Index is reportedas the lost mass in grams per foot of travel of a weighted foam block,multiplied by 100, when the foam is moved through a completesixteen-inch test cycle. The procedure used is a modified form of ASTMF1015, “Standard Test Method for Relative Abrasiveness of Synthetic TurfPlaying Surfaces.” A higher Abrasiveness Index is taken to be indicativeof a more abrasive surface.

[0216] To prepare for measurement of the Abrasiveness Index, foam testblocks are cut from a phenolic foam material to have dimensions of 1inch by 1 inch by 1.25 inches. The foam is a well known commercial greenfoam marketed as “Dry Floral Foam,” product code 665018/63486APP,manufactured by Oasis Floral Products, a division of Smithers-OasisCompany of Kent, Ohio (UPC 082322634866), commonly used for floralarrangements for silk flowers and dried flowers.

[0217] A sample is cut from the material to be tested and taped to aflat, rigid table surface using two-sided Manco® Indoor/Outdoor CarpetTape, marketed by Manco, Inc. of the Henkel Group of Avon, Ohio (UPC075353071984). The tape is first placed on the table surface, avoidingoverlapping of tape segments to ensure that a substantially uniformadhesive surface is provided having dimensions of at least 4 inches by 4inches. The sample is then centered over the taped region and gentlypressed into place. A 3-inch by 3-inch square plastic block with athickness of 1-inch and mass of 168 grams is placed on the sample todefine a test area that is centered within at least a 4-inch by 4-inchregion of the table having the double-sided tape. A brass cylinder,2-inches in diameter with a mass of 1 kg is centered on the plasticblock and allowed to reside for 10 seconds to secure the sample to thetaped region. A marker is used to trace around the border of the plasticblock to draw the test area. The block and weight are removed from thesample. The sides of the drawn square (3-inches by 3-inches) should bealigned with the machine-direction and cross-direction of the materialbeing tested, when such directions are defined (e.g., the shutedirection for a woven abrasive layer).

[0218]FIG. 25 is a schematic of the set-up for the Abrasiveness Indextest for the sample 280 to be tested. The sample 280 may have anupwardly facing abrasive layer 32 which may be joined to an underlyingtissue web (not shown). Double-sided tape 270 joins the sample 280 to atable surface (not shown). A foam block 274 is placed in the lowerright-hand corner 282A of the square test region 272 marked on the uppersurface of the sample 280. The dimensions of the surface of the foamblock 274 contacting the sample 280 are 1-inch by 1-inch. On top of thefoam block 274 is placed a 100 g brass weight 276 having a circularfootprint 1-inch in diameter. Two sides of the foam block 274 on thesample 280 are substantially superimposed over the inside boundary ofthe corner 282A of the marked test region 272.

[0219] To conduct the test, the foam block 274 is steadily moved by handfrom the lower right-hand corner 282A (the initial corner) to the upperright-hand corner 282B of the test region 272, and then to the othercorners 282C, 282D, and back to 282A again, ensuring that the foam block274 travels along but not outside of the boundaries of the marked testarea 272. Care is taken not to apply downward or upward force by hand,but to apply only steady lateral force to move the foam block 274successively from one corner to another as indicated by the arrows278A-278D. Both hands of the operator may be used as necessary tomaintain the uprightness of the weighted foam block 274. The block ismoved at a steady rate of about 5 seconds per side (a side being thepath from one corner to the next corner). The path traced by the foamblock 274 defines a square, ending at the initial corner 282A.

[0220] To achieve a smooth, steady motion, one finger (e.g., the thumb)should be on the “rear” vertical surface of the foam block 274 to pushthe block in the desired direction, and another finger should be on the“forward” vertical surface to maintain a steady position of the foamblock 274.

[0221] After the block 274 has returned to the initial corner 282A, thepath is reversed, again without lifting the weighted block 274. Theblock 274 thus follows the same path it once traced but in reverseorder, going from the initial corner 282A to the lower left-hand corner282D to the upper left-hand corner 282C to the upper right-hand corner282B back to the initial lower right-hand corner 282A, being moved bysteady lateral pressure and maintaining a rate of 5 seconds per side.

[0222] During this process, a portion of the foam block 274 will havebeen removed by abrasion during the 16-inch total path it travels (twoeight-inch cycles). The 100-gram weight 276 is removed and the foamblock 274 is then weighed and the amount of the foam block 274 removedby abrasion is determined by difference and recorded. This process isrepeated two more times, using new materials (new double-sided tape 270,new samples 280 of the same material being tested, and new foam blocks274), allowing the lost mass to be determined three times. The averageof the three measurements is taken and converted to mass lost per 12inches by multiplication with the correction factor of 12/16 (i.e.,normalized to a path of 12 inches), and then multiplied by 100. Theresulting parameter is reported as the Abrasiveness Index for thematerial being tested.

[0223] The abrasive layers of the present invention may have anAbrasiveness Index of about 1 or greater, about 2 or greater, about 3 orgreater, about 4 or greater, or about 5 or greater, such as from about1.5 to 10, or from about 2 to about 7.

EXAMPLE 1

[0224] Preparation of an Uncreped Through dried Basesheet

[0225] To demonstrate an example of a textured, wet resilient absorbentweb with improved dry feel, a suitable basesheet was prepared. Thebasesheet was produced on a continuous tissue-making machine adapted foruncreped through-air drying. The machine comprises a Fourdrinier formingsection, a transfer section, a through-drying section, a subsequenttransfer section and a reel. A dilute aqueous slurry at approximately 1%consistency was prepared from 100% bleached chemithermomechanical pulp(BCTMP), pulped for 45 minutes at about 4% consistency prior todilution. The BCTMP is commercially available as Millar-Western500/80/00 (Millar-Western, Meadow Lake, Saskatchewan, Canada). Kymene557LX wet strength agent, manufactured by Hercules, Inc. (Wilmington,Del.) was added to the aqueous slurry at a dosage of about 16 kg ofKymene per ton of dry fiber, as was carboxymethylcellulose at a dose of1.5 kg per ton of dry fiber. The slurry was then deposited on a fineforming fabric and dewatered by vacuum boxes to form a web with aconsistency of about 12%. The web was then transferred to a transferfabric (Lindsay Wire T-807-1) using a vacuum shoe at a first transferpoint with no significant speed differential between the two fabrics,which were traveling at about 5.0 meters per second (980 feet perminute). The web was further transferred from the transfer fabric to awoven through-drying fabric at a second transfer point using a secondvacuum shoe. The through drying fabric used was a Lindsay Wire T-116-3design (Lindsay Wire Division, Appleton Mills, Appleton, Wis.). TheT-116-3 fabric is well suited for creating molded, three-dimensionalstructures. At the second transfer point, the through-drying fabric wastraveling more slowly than the transfer fabric, with a velocitydifferential of 27%. The web was then passed into a hooded through dryerwhere the sheet was dried. The dried sheet was then transferred from thethrough-drying fabric to another fabric, from which the sheet wasreeled. The basis weight of the dry basesheet was approximately 30 gsm(grams per square meter). The sheet had a thickness of about 1 mm, anOverall Surface Depth of about 0.4 mm, a geometric mean tensile strengthof about 1000 grams per 3 inches (measured with a 4-inch jaw span and a10-inch-per minute crosshead speed at 50% relative humidity and 22.8°C.), a wet:dry tensile ratio of 45% in the cross-direction, an MD:CDtensile ratio of 1.25, and 17% MD stretch, 8.5% CD stretch.

[0226] The Air Permeability of the web was measured at 440 CFM.

EXAMPLE 2

[0227] A Laminate with a First Meltblown Polypropylene Web

[0228] High molecular weight isotactic polypropylene, Achieve 3915manufactured by ExxonMobil Chemical Comp. (Houston, Tex.) was used in apilot meltblown facility to make a polymer network by meltblownfiberization. The molecular weight range of the polymer is about 130,000to 140,000. According to the manufacturer, the melt flow rate of thepolymer according to ASTM D 1238 is 70 g/10 min, which is believed to bebelow the range of melt flow rates for polymers typically used in ameltblown operation; the polymer is normally used for a spunbondoperation or other applications other than meltblowing. (For example, atypical meltblown polymer such as polypropylene PP3546G of ExxonMobilChemical Corp. has a melt flow rate of 1200 g/10 min, measured accordingto ASTM D 1238, and polypropylene PP3746G of the same manufacturer has amelt flow rate of 1500 g/10 min.) The high viscosity material was foundto be surprisingly useful for producing the a coarse meltblown webaccording to the present invention.

[0229] The polypropylene was extruded through a meltblown die at 485° F.on a porous Teflon conveyor web with an underlying vacuum. The web speedwas 10 ft/min. A meltblown polypropylene network with a basis weight of85 to 120 gsm was generated by adjusting the temperature, air pressure,and the distance between the blown head to the forming table, as well asthe flow rate of the polymer.

[0230]FIG. 12 is a schematic drawing of a central cutaway portion of themeltblown die 120 drawn according to the meltblown die used in thisExample. The primary portion of the die comprises two side blocks 242,242′, and a triangular central feed block 244 through which polymer isinjected into an internal chamber 250. The central feed block 244 issubstantially an isosceles triangle in cross-section, converging to anapex 246 at a 60-degree angle. Along the apex 246 are drilled a seriesof evenly spaced holes 248 in fluid communication with the internalchamber 250. The internal chamber 250 is also in fluid communicationwith a pressurized source of molten polymer (not shown) which forcesmolten polymer through the holes 248 of the central feed block 244 toform strands of polymer (not shown). Air jets 258, 258′ flow through thegaps 252, 252′, respectively, between the side blocks 242, 242′ and thecentral feed block 244. The gaps 252, 252′ are in fluid communicationwith a source of pressurized air (not shown) which generates the flow ofthe air jets 258, 258′ toward the apex 246 of the central feed block244. The air in the jets 258, 258′ is typically heated well above themelting point of the polymer to prevent premature cooling of the polymerstrands. For this Example, the air temperature was about 480° F. Inconventional meltblown operation, the air jets 258, 258′ provide a highlevel of shear that may cause extensional thinning of the polymerstrands and also provide a high level of turbulence to separate thestrands and create isolated, randomly positioned fibers. For purposes ofthe present invention, however, the air flow rate may be decreased toreduce turbulence, allowing some adjacent polymer strands from adjacentholes 248 to coalesce into multifilamentary aggregates, which stillprovide enough air flow and turbulence to deposit the polymer strands asa network of fibers on an underlying carrier web (not shown).

[0231] The holes 248 have a diameter of 0.015 inches and were drilled at30 per inch. The width of the active region of the die 120 (the regionprovided with holes 248 for formation of polymer strands) was 11.5inches. The entire die 120 was 14 inches wide. The gaps 252, 252′ had awidth of 0.055 inches, determined by shims placed between the centralfeed block 244 and the side blocks 242, 242′ at the outside ends of thedie 120 (not shown), away from the active region. The drill depth 256 ofthe holes 248 is the distance into the central feed block 244 that hadto be penetrated during drilling to each the central chamber 250. Inthis case, the drill depth was about 4 mm. The height of the centralfeed block 244 (the distance from the base 254 to the apex 246) was 52mm, and the depth of the internal chamber 250 (the height of the centralfeed block 244 minus the drill depth 256) was about 48 mm.

[0232] Not shown is a backing plate for the die block 120 through whichpressurized polymer melt was injected, the air injection lines, andsupporting structures for the die. Such features are well known andeasily provided by those skilled in the art. (It should be recognizedthat numerous alternatives to the meltblown die of FIG. 12 are stillwithin the scope of the present invention, such as a die with two ormore rows of holes 248 that may be arranged in a staggered array,parallel lines, and the like, or dies in which annular jets or airsurround the exiting polymer strand.)

[0233] In producing the meltblown web with coarse multifilamentaryaggregates, it was found that the “normal” elevation of the meltblowndie relative to the carrier wire, namely, 11 inches, was too high forthe modified run conditions according to the present invention. At thisnormal height, the strands had become too cool when they hit the wirefor good fiber to fiber bonding (here the term “fiber” encompassesmultifilamentary aggregates), and the resulting web lacked integrity.The head was then lowered several inches, allowing good fiber-fiberbonding to occur. The distance from the die's apex to the carrier wirewas about 7 inches. In practice, the optimum height for a given polymerwill be a function of web speed (and thus the flow rate of the polymer)and the temperatures of both the polymer and the heated air.

[0234] For the system shown in FIG. 12, conventional meltblown operationis achieved when the pressurized air source applied to the air gaps 252,252′ is about 40 to 50 psig. For the present Example, however, whenlower airflow rates were desired to produce coarser fibers, thepressurized air source was set to about 12 psig to 20 psig during theruns to yield a durable abrasive network with good material propertiesfor the purposes of the present invention. Thus, less than about halfthe air flow rate of conventional meltblown operation was used.

[0235] A micrometer (Fowler Precision Tools, Model S2-550-020) was usedto measure the diameter of the polypropylene fibers in the meltblownmaterial. Twenty fibers were randomly selected and measured. A range of70 microns to 485 microns was obtained, with a mean of 250 microns and astandard deviation of 130 microns. Multifilamentary aggregates formed asignificant portion of the meltblown web.

[0236] Testing of Thickness Variation, as previously described, in oneset of samples (measured basis weight of 120 gsm) gave a standarddeviation of 0.25 mm (mean thickness was 1.18 mm) for the meltblown web.By way of comparison, a more conventional meltblown web produced atKimberly-Clark for commercial with a basis weight of 39 gsm was measuredto have a standard deviation of 0.03 mm (mean thickness was 0.29 mm).

[0237] Gurley stiffness measurements of the meltblown web gave anaverage MD stiffness of 138.8 mg, with a standard deviation of 35.9 mg.The CD stiffness was 150 mg, with a standard deviation of 34.0 mg. Thebasis weight of the measured samples was 120 gsm.

[0238] The Air Permeability of the meltblown web with multifilamentaryaggregates was measured at 1130 CFM (mean of 6 samples). When two layersof the meltblown were superimposed, the Air Permeability for the twolayers together was measured at 797 CFM (mean of three measurementlocations).

[0239] The meltblown web was joined to the uncreped tissue web ofExample 1. In a first run (Run 2-A), the meltblown web was joined to acut section of the uncreped through-dried tissue web to make a firstlaminate using a hot melt adhesive (NS-5610, National Starch ChemicalCompany of Berkeley, Calif.) applied in a swirl spray pattern at 320° F.with a hot melt applicator. The meltblown web showed excellent adhesionand performed well in scrubbing (high scratch resistance).

[0240] In a second run (Run 2-B), the meltblown web was joined to thetissue web to make a second laminate using thermal bonding achieved witha Sunbeam® Model 3953-006 1200 Watt iron on the highest (“linen”) heatsetting. The tissue web, cut to three-inches by six-inches, was placedover a meltblown web cut to the same size, and the iron was placed onthe tissue web and pressed with mild pressure (ca. 10 lbs of force) forabout two to three seconds, then lifted and placed on an adjacent spot.This was repeated several times, with each spot of the tissue typicallybeing contacted with the iron for two or three times, until themeltblown web became well bonded with the tissue without the meltblownweb losing its abrasive characteristics. (In practice, temperature,application pressure, and duration of heating may all be optimized forthe particular product being made.)

[0241] The Air Permeability of a cut sample of the laminate was measuredat 316 CFM.

[0242] The surface topography of the second laminate was measured usingmoiré interferometry, as previously described. A 38-mm field of viewoptical head (nominally 35-mm) was used. To improve the opacity of thepolypropylene fibers, the sample was lightly played with a flat whitespray paint, using a can of Krylon® 1502 flat white paint(Sherwin-Williams, Cleveland, Ohio), sprayed from a distance of about 6inches with a sweeping motion and about 2 seconds of residence time formost portions of the painted laminate. The applied paint did not appearto fill or block pores that were visible to the eye on the tissue, anddid not appear to significantly modify the topography of the surface.The Air Permeability of the lightly painted laminate was measured at 306CFM.

[0243]FIG. 13 is a micrograph of the unpainted meltblown-tissue laminate200 of Run 2-B taken from above (the plan view). The micrograph showsthe thermoplastic polymeric fibers 126 of an abrasive meltblown layer 32above a paper web 34 comprising papermaking fibers 127 of substantiallysmaller diameter and smaller length than the thermoplastic polymericfibers 126. The meltblown layer 32 appears to consist almost entirely ofmultifilamentary aggregates 240 having more than two polymeric strandsjoined together in ribbon-like structures disposed somewhat randomly onthe paper web 34. The length scale is indicated by the gray bar 211which has a length of 2500 microns (2.5 mm) on the micrograph. It can beseen that the multifilamentary aggregates have widths ranging from about100 to about 500 microns.

[0244] Several of the multifilamentary aggregates 240 in FIG. 13 twist180 degrees or more over a short distance. Without wishing to be boundby theory, it is believed that the common twisting of themultifilamentary aggregates 240 presents a more abrasive surface than ifthe multifilamentary aggregates 240 remains substantially flat (relativeto the paper web) and untwisted. In one embodiment, a region of 3centimeters square (3 cm×3 cm) will have, on the average (based onsampling at least 20 representative 3 cm square regions), at least onemultifilamentary aggregate making a twist of at least 180 degrees aboutits axis. More specifically, there may be at least 5, at least 10, atleast 15, or at least 50 multifilamentary aggregates that each undergo atwist along their respective axes of at least 180 degrees, and in oneembodiment, at least 360 degrees or at least 720 degrees. In oneembodiment, at least one multifilamentary aggregate in the 3 cm squarearea has a helically twisted structure such that a 360 twist occurswithin a distance of no more than 3 cm, more specifically no more than 1cm, along the length of the fiber (following the path of the fiber).

[0245]FIG. 14A is a micrograph of the cross-section of themeltblown-tissue laminate 200 of Run 2-B showing the abrasive meltblownlayer 32 comprising multifilamentary aggregates 240 disposed above thepaper web 34. Fused regions 260 may be seen in the meltblown layer 32apparently caused by heating of the paper web 34 with an iron during theattachment process. In the paper web 34, an elevated region 262 may beseen due to molding of the paper web 34 during through drying. Suchtopographical structures, formed during non-compressive drying of theweb, are remarkably wet resilient since the hydrogen bonds between thepapermaking fibers 127 are formed in the three-dimensional state, not aflat, dense state as in creping. When a creped web is wetted, the bulkystructure added in the form of kinks and microcompressions to dry fibersduring creping become relaxed as the moist fibers swell, so the crepedweb thus tends to return to a flat, dense state upon wetting. But whenan uncreped, through-dried three-dimensional web is wetted, thestructure is largely maintained. Further, the molded, three-dimensionaltopography of the paper web 34 in FIG. 14A may also contribute to thetopography of the meltblown layer 32, improving the abrasiveness of themeltblown layer 32 and improving the ability of the meltblown-tissuelaminate 200 to clean or wipe. Unlike embossed webs, the uncreped,through dried paper web 34 in FIG. 14A has a three-dimensional structurehaving substantially uniform density.

[0246] Some of the multifilamentary aggregates 240 shown have a ribbonlike structure with multiple strands substantially aligned, but othersshow a staggered structure or have strands that vary in positionrelative to one another. The multifilamentary aggregates 240 have threeor more strands 238, and based on FIG. 14A it appears thatmultifilamentary aggregates 240 with four or more strands 238 comprisewell over 50 weight % (e.g., perhaps over 90 weight %) of the meltblownlayer 32.

[0247]FIG. 14B is a micrograph of a cross-section of themeltblown-tissue laminate 200 of Run 2-B that has been very lightlysprayed with white spray paint (the Krylon© paint described above). Themultifilamentary aggregate 240 labeled as “J” executes a twist of about180 degrees relative to its axis (an axial twist) over a fiber pathlength of about 1 mm. In other words, the side of the multifilamentaryaggregate 240 labeled as “J” that was away from the paper web 34 afterthe twist is then facing the paper web 34.

[0248] For the laminate of Run 2-B, the measured topography of theabrasive layer on the underlying uncreped through-dried tissue may beseen graphically in FIG. 15, which shows a screen shot 140 oftopographical data for the meltblown-tissue laminate generated by theCADEYES® system, customized to show a 512×512 pixel height map 142 witha profile display box 144 to the right of the height map 142 showing aprofile 146 corresponding to the height profile along a profile line 156on the height map 142. The profile shows a variety of peaks 148 andvalleys 150 corresponding to elevated and depressed regions,respectively, along the profile line 156. In the approximately 38-mmsquare region depicted in the height map 142, the lightest regionscorrespond to the highest height measurements and the darkest regionscorrespond to lowest heights of the measured surface. In the profile box144, the 10% material line 152 and the 90% material line 154 are shown,and the gap in height between the two lines 152, 154 is reported as1.456 mm, meaning that the surface depth along the profile line 156across the height map 142 is 1.456 mm.

[0249] Some portions of the profile 146, such as the valley 150 a,correspond with the surface of the tissue web beneath the meltblownabrasive layer. Thus, there are portions of the surface area of themeltblown abrasive layer occupied by openings that extend through to theunderlying surface of the tissue web, allowing the tissue web to be seenwhen viewed from above. Additional openings to the tissue web arevisible under a microscope at low (10×) magnification. With theresolution of the CADEYES® device in a 38-mm field of view, it issometimes difficult to distinguish small openings that extend to thetissue below.

[0250] In the upper right hand portion of the height map 142, somenon-fibrous regions appear unusually white in an otherwise depressedregion. This is believed to be due to optical noise since the signalstrength in this region was low, causing a step discontinuity in thefringe to which the data was assigned. There are also scattered pixelsfor which no measurement was possible, but in general the fibrous natureof the meltblown web was captured by the moiré interferometrymeasurement.

[0251]FIG. 16 provides a screen shot 140 of the same height map 142, butwith a different profile line 156 selected to provide a differentprofile 146 extracted from the height map data. Here the lines 152 and154 were manually selected and do not necessarily correspond to the 10%and 90% material lines, but reflect an attempt to identifycharacteristic peak and valley heights on the profile 146, showing adepth of about 1.7 mm. The valley 150 a corresponds to a portion of theunderlying tissue web, suggesting that the thickness of the abrasivelayer on the tissue web is roughly 1.7 mm.

[0252] In regions 158 a and 158 b, the meltblown web is thin enough thathorizontal bands from the texture of the underlying three-dimensionaltissue can be seen. Thus, the meltblown web has regions of high and lowconcentration of fibers (high and low basis weight), such that regionsof the underlying tissue can be seen that are greater in size than 1 mmby 2 mm or greater than 2 mm by 4 mm (i.e., regions with such dimensionsare substantially free of abrasive polymeric fibers).

[0253] Ten samples made from Run 2-B were tested for Wet and DryOpacity. Average Dry Opacity was 67.65% (standard deviation 1.14%), andthe average Wet Opacity was 53.97% (standard deviation 3.1%), with anaverage of 1.60 grams of water per gram of fiber in the wetted samples(standard deviation 0.15 grams of water per gram of fiber). By way ofcomparison, a Chore Boy® Golden Fleece™ Scouring Cloth (UPC # 0 2660030316 7), marketed by Reckitt & Colman Inc. Wayne, N.J., showed DryOpacity of 95.1% for three samples, a Wet Opacity of 95.83%, and a waterpickup of 0.54 grams of water per gram of solid (standard deviation of0.16 gram of water per gram of solid).

[0254] In a third run (Run 2-C), the meltblown web was thermally bondedto plain white SCOTT® Towel (UPC 054000173431—core code JE2 11 290 01)produced by Kimberly-Clark Corp. (Dallas, Tex.) by ironing, as describedfor Run 2-B above. The Air Permeability was measured at 118 CFM, whiletwo samples of the SCOTT® Towel tissue alone taken from different rollswere measured at 140 CFM and 135 CFM. A sample of the meltblown websimply placed on top of the SCOTT® Towel tissue sample with an AirPermeability value of 135 CFM, overlaid without thermal bonding of thetwo layers, yielded an Air Permeability of 134 CFM, suggesting that theprocess of thermal bonding causes obstruction of some pores in thetissue web to slightly reduce the Air Permeability relative to anunbonded combination of the tissue and the abrasive layer.

[0255]FIG. 17 is a plan-view micrograph of meltblown-tissue laminate 200of Run 2-C showing the abrasive meltblown layer 32 comprising polymericfibers 126 primarily in the form of multifilamentary aggregates 240disposed above a paper web 34 (SCOTT® Towel). Fused regions 260 of themeltblown layer 32 can be seen joined to the paper web 34.

[0256] Some of the multifilamentary aggregates 240 shown have a ribbonlike structure with multiple strands 238 that are substantially parallelfor a distance, after which some of the strands 238 may separate. Oneexample is provided by the multifilamentary aggregate 240 labeled “M.”Three circles indicate the location of apparent forks 261 where aportion of a multifilamentary aggregate 240 departs from the remainderof the multifilamentary aggregate 240 and follows a different direction.In one embodiment, a 3 cm square region of a meltblown web 32 havingmultifilamentary aggregates 240 may comprise, on the average (based onan average of at least 20 sections measured), at least 3 forked regions261 in the multifilamentary aggregates 240, and more specifically atleast 10 forked regions in the multifilamentary aggregates 240, and mostspecifically at least 30 forked regions in the multifilamentaryaggregates 240.

[0257]FIG. 18 is a micrograph of the cross-section of themeltblown-tissue laminate 200 of Run 2-C. A fused region 260 beneath onemultifilamentary aggregate 240 appears to be joined to the paper web 34.Numerous strands 138 are evident in the multifilamentary aggregates 240,with strand counts on the order of about 10 being present.

[0258] In a fourth run (Run 2-D), the meltblown web was thermally bondedto commercially available VIVA® towel, produced by Kimberly-Clark Corp.(Dallas, Tex.) by ironing, as described for Run 2-B above. The AirPermeability was measured at 97.1 CFM.

[0259]FIG. 19 is a plan-view micrograph of a meltblown-tissue laminate200 of Run 2-D showing the abrasive meltblown layer 32 comprisingpolymeric fibers 126 primarily in the form of multifilamentaryaggregates 240 disposed above a paper web 34 (VIVA® Towel). Latex-bondedregions 263 in the paper web 34 can seen, which are a result of thedouble recreped manufacturing process for this web.

[0260] In a related trial, a similar polymer was used to create anothermeltblown polymer web according to the methods described in thisExample. Instead of Achieve 3915 polypropylene by ExxonMobil ChemicalCorp., Achieve 3825 polypropylene was used to produce a meltblown webwith similar properties to that obtained with the Achieve 3915 polymer.The Achieve 3825 polypropylene is a metallocene grade polypropylenehaving a melt flow rate of 32 g/10 min. Multifilamentary aggregates werealso produced with similar characteristics to those obtained with theAchieve 3915 polymer. Higher back pressure was required to extrude themolten Achieve 3825 polymer, requiring about 400 psig in comparison to280 psig for the Achieve 3915, due to the lower melt flow rate.

EXAMPLE 3

[0261] A Second Meltblown Polypropylene Web

[0262] Bassell PF015 polypropylene manufactured by Bassell North America(Wilmington, Del.) having a nominal processing temperature of about 221°C. was used to produce a second meltblown polypropylene web to be usedin making laminates with tissue. A pilot facility distinct from that ofExample 2 was used. The meltblown web was produced through a meltblowntip (30 holes per inch, hole diameter 0.0145 inches) producing 4 poundsper inch of machine width per hour (4 PIH). Coarseness in the fiber wasachieved by progressively lowering processing temperatures and primaryair pressure while targeting basis weights varying between about 50 gsmand 100 gsm. For 50 gsm meltblown, the line speed was 78 feet perminute, and for 100 gsm meltblown, the line speed was 39 feet perminute. Initial processing temperatures of about 500° F. (260° C.) werelowered to between about 392° F. (200° C.) to about 410° F. (210° C.),with the die tip at 410° F. (210° C.). Primary air pressure was loweredfrom the normal range of 3.5-4 psig to less than 0.5 psig. Dietip andspinpump pressures were about 170-190 psig and 340-370 psig,respectively. These settings were reached iteratively in order to obtaina coarse meltblown web, with good abrasiveness by virtue of being moldedagainst the carrier wire. In conventional operation, meltblown fibersare relatively solidified when they land on the carrier wire and are notmolded to a significant degree against the carrier wire, but in thiscase the meltblown fibers were still soft enough that they could conformto the texture of the carrier wire such that the meltblown web receiveda molded, abrasive texture.

[0263] The meltblown was formed at basis weights of about 50 gsm and atabout 100 gsm as a stand-alone product, and also deposited directly onthe UCTAD tissue of Example 1 and on commercial VIVA® paper towels. Themeltblown web alone was measured to have an average MD Gurley Stiffnessvalue of 113.7 mg (standard deviation of 34.5 mg) and an average CDGurley Stiffness value of 113.0 mg (standard deviation of 41.9 mg). Thetested samples had a basis weight of 100 gsm.

[0264] Testing of Thickness Variation, as previously described, in oneset of high-basis weight samples (measured basis weight of 100 gsm) gavea standard deviation of 0.07 mm (mean thickness was 0.99 mm) for themeltblown web.

[0265] Measurement of Air Permeability for a single layer of themeltblown gave a value in excess of 1500 CFM. Two superimposed plies ofthe meltblown web gave an Air Permeability of 1168 CFM (mean ofmeasurements at six locations).

[0266] In one run (Run 3-A), the same uncreped through-dried tissue madein Example 1 was used, with 50 gsm meltblown being formed directly onthe tissue web. FIG. 20 shows a height map 142 of the laminate with themeltblown layer up. A profile 146 taken along a profile line 156 fromthe height map 142 yields Surface Depth of about 0.728 mm (thedifference in height between the 10% material line 152 and the 90%material line 154). A repeating structure can be seen corresponding withthe topography of the carrier wire against which the meltblown web wasmolded during formation. A unit cell 153 of the repeating structure isindicated, which is a parallelogram having sides of about 9.5 mm and 1.5mm.

[0267]FIG. 21 is a plan-view micrograph of the meltblown-tissue laminate200 of Run 3-A that was sprayed lightly with white spray paint (Krylon®1502 flat white paint of Sherwin-Williams, Cleveland, Ohio),demonstrating that particulate matter 265 may be bonded to the polymericfibers 126 if desired. The coarse polymeric fibers 126 in thisembodiment are generally single strands 238. Fused regions 260 of themeltblown layer 32 can be seen joined to the paper web 34.

[0268]FIG. 22 is a micrograph of the cross-section of themeltblown-tissue laminate 200 of Run 3-A.

[0269] The laminate had an Air Permeability measured at 381 CFM (mean ofmeasurements at six locations).

[0270] Some runs were also conducted by inverting the web after themeltblown layer had been formed on one surface, and again applying ameltblown layer to the opposing surface such that the tissue had anabrasive layer on both sides.

[0271] Another set of samples (Run 3-B) were prepared by ironing themeltblown web with the tissue of Example 1, following the ironingprocedures given in Example 2. Eight samples were tested for Wet and DryOpacity. Average Dry Opacity was 64.0% (standard deviation 0.82%), andthe average Wet Opacity was 47.2% (standard deviation 2.2%), with anaverage of 1.59 grams of water per gram of fiber in the wetted samples(standard deviation 0.10 grams of water per gram of fiber).

[0272] Another laminate (Run 3-C) was produced by forming the meltblownweb directly on a VIVA® paper towel.

[0273] Laminates were also made by joining the abrasive layer to ahydroentangled wiper using a hotmelt adhesive applied in a swirlpattern. The wiper, manufactured by Kimberly-Clark Corporation (Dallas,Tex.), was WypAll® Teri® wipes, whose package is marked with U.S. Pat.No. 5,284,703, issued Feb. 8, 1994 to Everhart et al., which discloses acomposite fabric containing more than about 70 percent, by weight, pulpfibers which are hydraulically entangled into a continuous filamentsubstrate (e.g., a spunbond web).

EXAMPLE 4

[0274] Variation of the Second Meltblown Web

[0275] A meltblown web was made according to Example 3, but with severalvariations such that little molding against the carrier wire could occur(lower air temperature and larger distance from the die tip to thecarrier wire, allowing the meltblown fibers to cool more quickly).Though fibers were still coarser than conventional meltblown fibers, theabrasive character of the meltblown web was tangibly reduced due to thelack of large-scale topography imparted to the meltblown web. (Themeltblown web appeared to be free of multifilamentary aggregates, which,it is believed, if present, would have contributed to a higher abrasivecharacteristic regardless of the macroscopic topography imparted bymolding against a carrier wire.)

EXAMPLE 5

[0276] Synergistic Material Properties

[0277] To demonstrate the Strength Synergy and Stretch Synergy ofseveral embodiments of the present invention, tensile testing was doneof laminates and unbonded layers using the first meltblown web ofExample 2. Results are shown in Table 1 below, where tests are reportedas averages for multiple samples (five samples per measurement). Themeltblown web alone had a mean tensile strength of 3393 grams per 3inches (measured with a 4-inch gage length and 10-in-per-minutecrosshead speed with an Instron Universal Testing Machine). When placedadjacent to a sample of Scott® towel (a commercial uncreped through-airdried tissue web comprising about 25% high-yield pulp fibers and wetstrength resins) but not bonded thereto (the two webs were superimposedand tested together), the tensile strength was 3707 g/3-in. When themeltblown web was thermally bonded (as described in Example 2) to theScott® towel, the tensile strength increased to 5385 g/3-in, an increaseof 45%, giving a Strength Synergy of 1.45. The Stretch Synergy was 2.06.

[0278] In another run, the meltblown web was tested together with theuncreped through-air dried tissue web of Example 1 (labeled as “30 gsmUCTAD”), giving an average tensile strength of 3565 g/3-in when the twowebs were unbonded, but an average tensile strength 3915 g/3-in for websthat were thermally bonded, for a Strength Synergy of about 1.10. TheStretch Synergy was 1.36.

[0279] In a third run, VIVA® towel was used as the tissue. The StrengthSynergy was 1.22, and the Stretch Synergy was 1.44. TABLE 1 Measurementsof Strength and Stretch Synergy Basis Tensile Sample Wt., Strength, St.Strength Stretch, St. Stretch Description gsm g/3 in. Dev Synergy % DevSynergy Meltblown 120 3393 461 — 3.26 0.51 — MB alone SCOTT ® 43.5 276365 — 18.65 0.56 — Towel Towel + MB, 163.5 3707 750 — 3.18 0.80 —Unbonded Towel + MB, 163.5 5385 1099 1.45 6.54 0.88 2.06 Bonded 30 gsm32.5 1136 36 — 17.19 0.72 — UCTAD UCTAD + 152.5 3565 787 — 2.94 0.53 —MB, Unbonded UCTAD + 152.5 3915 575 1.10 4.00 0.49 1.36 MB, BondedVIVA ® Towel 67 2092 60 — 26.66 0.28 — VIVA + MB, 187 3460 1092 — 3.270.86 — Unbonded VIVA + MB, 187 4228 838 1.22 4.72 1.2 1.44 Bonded

EXAMPLE 6

[0280] Abrasive Properties

[0281] To illustrate the abrasiveness of products of the presentinvention and commercially available scrubbing materials, Abrasive Indextests were conducted for a variety of samples made according to thepresent invention, as described in Examples 2 through 4, as well as forfive commercial products marketed for scrubbing and cleaning, theproducts each comprising an abrasive layer of material.

[0282] The five commercial products were: A) the O-Cel-O™ Heavy DutyScrub Pad (UPC 053200072056), marketed by 3M Home Care Products (St.Paul, Minn.); B) Scotch Brite™ Heavy Duty Scrub Pad (UPC 051131502185),also marketed by 3M Home Care Products (St. Paul, Minn.), a producthaving a dark maroon-colored reticulated polymeric material believed tocomprise polypropylene and other materials, C) the Scotch Brite™Delicate Duty Scrub Sponge (UPC 021200000027), also marketed by 3M HomeCare Products (St. Paul, Minn.)—the abrasive layer of this product wasdetached from the sponge for testing; D) Chore Boy™ Golden Fleece™Scouring Cloth (UPC 026600313167), marketed by Reckitt & Colman, Inc.(Wayne, N.J.)., and E) a Sani-Tuff™ wiper, marketed by Kimberly-ClarkCorp. (Houston, Tex.), which comprises a green colored meltblown layeron asynthetic polymer web (a heavier meltblown web), with a basis weightof about 33 gsm. The dry Sani-Tuff™ wiper had an Air Permeability of98.5 CFM (mean of three measurements).

[0283] Table 2 displays the Abrasive Index results. Interestingly, themeltblown web of Example 2, comprising a significant number ofmultifilamentary aggregates, displayed the highest Abrasiveness Index(about 5.5). The material of Run 2-D, wherein the meltblown web ofExample 2 had been ironed onto a relatively smooth VIVA® paper towel,displayed a high Abrasiveness Index as well (about 4.25). The slightlylower Abrasiveness Index compared to the isolated meltblown web itselfmay be due to a slight decrease in surface depth of the meltblown causedby the attachment process.

[0284] The isolated meltblown web of Example 3 displayed a highAbrasiveness Index (about 4.5), though not as high as the meltblown webof Example 2 with multifilamentary aggregates. This abrasive materialhad a macroscopic topography imparted by a coarse carrier fabric, which,it is believed, contributed to its abrasiveness. For Run 3-A, themeltblown web was no longer able to receive texture from the carrierwire, for it was formed directly on the tissue of Example 1. However,the highly textured tissue is believed to have provided a macroscopictopography to the meltblown web that provided good abrasivenessnevertheless, possibly accounting for the high Abrasiveness Index (about4) for the material of Run 3-A. However, when the meltblown web inExample 2 was formed on a relatively smooth VIVA® paper towel, whichlacks the distinctive topography and high surface depth of the UCTADtissue, the resulting Abrasiveness Index was relatively low (about1.25), thus pointing to the importance of the topography of themeltblown web, wherein useful topographical features may be imparted byeffective molding against a suitable carrier wire, or by formation ofthe meltblown web directly on a tissue web having good topography (e.g.,a surface depth of about 0.2 mm or greater, and optionally having arepeating pattern of peaks and valleys with a characteristic unit cellhaving an area of about 5 square millimeters or greater, or about 8square millimeters or greater).

[0285] The isolated meltblown web of Example 4 was formed on the samecarrier wire as in Example 3, but under conditions that did noteffectively mold the meltblown web against the topography of the carrierwire, resulting a relatively flat meltblown structure. This is believedto account for the relatively low Abrasiveness Index (about 1) found forthe meltblown web of Example 4. This meltblown web yielded an AirPermeability of 973 CFM (mean of 6 measurements on different locationsof the web).

[0286] The well-known abrasive features of commercial products A, B, andD are reflected in relatively high Abrasiveness Index values. Commercialproduct E, though intended for wiping purposes, employs a meltblownlayer lacking the coarseness or abrasive properties of many embodimentsof the present invention, and displayed a relatively low AbrasivenessIndex of about 0.75. TABLE 2 Comparative Abrasive Index Values FoamWeight, g Abrasiveness Index Sample Initial Final Specimen Avg.Meltblown of Example 2 0.68 0.61 5.25 5.5 0.69 0.62 5.25 0.68 0.6 6 Ex.2 Meltblown on VIVA 0.68 0.62 4.5 4.25 (Run 2-D) 0.67 0.6 5.25 0.68 0.643 Meltblown of Example 3 0.63 0.58 3.75 4.5 0.62 0.55 5.25 0.68 0.62 4.5Ex. 3 Meltblown on UCTAD 0.58 0.53 3.75 4 (Run 3-A) 0.65 0.59 4.5 0.670.62 3.75 Ex. 3 Meltblown on VIVA ® 0.63 0.62 0.75 1.25 (Run 3-C) 0.570.55 1.5 0.62 0.6 1.5 Meltblown of Example 4 0.64 0.63 0.75 1 0.65 0.640.75 0.64 0.62 1.5 Commercial Product A 0.69 0.63 4.5 4.75 0.65 0.585.25 0.66 0.6 4.5 Commercial Product B 0.64 0.57 5.25 4 0.65 0.6 3.750.74 0.7 3 Commercial Product C 0.66 0.63 2.25 2.5 0.66 0.62 3 0.64 0.612.25 Commercial Product D 0.66 0.59 5.25 5 0.64 0.58 4.5 0.67 0.6 5.25Commercial Product E 0.65 0.64 0.75 0.75 0.67 0.66 0.75 0.66 0.65 0.75

EXAMPLE 7

[0287] Prophetic Examples

[0288]FIG. 23 depicts a prophetic example showing a-cross-section of ascrubby pad 30 comprising an abrasive layer 32 having nonuniform heightrelative to the surface of an underlying absorbent fibrous layer 34,which also has a nonuniform thickness. In this embodiment, the thicknessof the abrasive layer 32 is greatest in regions where the height of theunderlying absorbent fibrous layer 34 is greatest, though otherpermutations (not shown) are possible, including one permutation inwhich the abrasive layer has a relatively lower thickness when theunderlying fibrous web 34 has greater thickness, height, or local basisweight than the average for the web, or permutations in which thethickness or basis weight variations of the abrasive layer vary somewhatindependently of structural variations in the absorbent fibrous web 34.

[0289] In the depicted embodiment of FIG. 23, the height and thicknessvariations of the abrasive layer 32 (which may correspond to variationsin basis weight or bulk or both of the abrasive layer 32, as well asvariations in other properties such as opacity and pore volume) have acharacteristic wavelength “WL” in the cross-section shown, which may betaken in the machine-direction, the cross-direction, or other in-planedirections of significance to a particular product such as directions at45-degree angles to the machine direction. In this case, the wavelength“WL” also corresponds with the wavelength of height variation in theunderlying absorbent fibrous layer 34.

[0290] The portions of the abrasive layer 32 over the depressed regionsof the absorbent fibrous layer 34 may represent regions that have beenthermally bonded for increased strength, causing higher density, or maybe regions of lower basis weight, or higher density produced duringmanufacturing, or may be regions that have been apertured to removematerial prior to joining to the absorbent fibrous web 34.

[0291] A related hypothetical example is shown in FIG. 24, where thefibrous web 34 has a first scrubby abrasive layer 32 on one side and asecond abrasive layer 32′ on the opposing side. Here both abrasivelayers 32, 32′ have nonuniform height and optionally density values thatvary with the topography of the absorbent fibrous layer 34. In thiscase, the two abrasive layers 32, 32′ vary out of phase with each other,such that apertures or regions with no abrasive material on a first sideof the absorbent web 34 are complemented by the presence of the abrasivematerial on the opposing side directly opposite to the region with noabrasive material on the absorbent web 34.

[0292] More than one layer of tissue or other absorbent fibrous webs maybe used in any of the laminates of the present invention.

[0293] These and other modifications and variations to the presentinvention may be practiced by those of ordinary skill in the art,without departing from the spirit and scope of the present invention,which is more particularly set forth in the appended claims. Inaddition, it should be understood that aspects of the variousembodiments may be interchanged both in whole or in part. Furthermore,those of ordinary skill in the art will appreciate that the foregoingdescription is by way of example only, and is not intended to limit theinvention so further described in such appended claims.

What is claimed is:
 1. A scrubbing product comprising: an abrasive layercomprising abrasive polymeric fibers in a non-uniform distribution suchthat the thickness of the abrasive layer varies across the width of theabrasive layer, said abrasive layer having an open, porous structurewith an Air Permeability greater than about 100; an absorbent layercomprising a fibrous cellulosic web; and wherein said abrasive layer issecured to said absorbent layer, said abrasive layer having a firstsurface which forms an outer surface of said scrubbing pad.
 2. Thescrubbing product of claim 1, wherein said cellulosic web comprises anuncreped, throughdried paper web.
 3. The scrubbing product of claim 1,wherein said cellulosic web comprises either an airlaid web or a coformweb.
 4. The scrubbing product of claim 1, further having a StrengthSynergy of about 1.05 or greater.
 5. The scrubbing product of claim 1,further having a Strength Synergy of about 1.2 or greater.
 6. Thescrubbing product of claim 1, further having a Stretch Synergy of about1.1 or greater.
 7. The scrubbing product of claim 1, further having aStretch Synergy of about 1.5 or greater.
 8. The scrubbing product ofclaim 1, further having an Air Permeability of about 30 cubic feet perminute or greater.
 9. The scrubbing product of claim 1, further havingan Air Permeability of about 60 cubic feet per minute or greater. 10.The scrubbing product of claim 1, further having an Air Permeability ofabout 80 cubic feet per minute or greater.
 11. The scrubbing product ofclaim 1, further having an Air Permeability of about 150 cubic feet perminute or greater.
 12. The scrubbing product of claim 1, wherein theproduct is substantially latex free.
 13. The scrubbing product of claim1, wherein the absorbent layer comprises latex binder.
 14. The scrubbingproduct of claim 1 having a machine direction Gurley stiffness of about2500 mg or less.
 15. The scrubbing product of claim 1 having a machinedirection Gurley stiffness of about 500 mg or less.
 16. The scrubbingproduct of claim 1, wherein the abrasive layer has a thickness variationof about 0.2 mm or greater.
 17. The scrubbing product of claim 1,wherein the abrasive layer has a thickness variation of about 1 mm orgreater.
 18. The scrubbing product of claim 1, wherein said abrasivefibers comprise thermoplastic polymer fibers having a melting point ofabout 120° C. or greater.
 19. The scrubbing product of claim 18, whereinsaid thermoplastic polymer is selected from the group consisting ofpolypropylene, polyethylene, polyesters, high-density polypropylene,polystyrene, polyamides, polyvinylidenes, polyvinyl chloride,polyurethane, polyurea, and copolymers thereof.
 20. The scrubbingproduct of claim 1, wherein said thermoplastic polymer is elastomeric.21. The scrubbing product of claim 1, wherein the thermoplastic polymeris not elastomeric.
 22. The scrubbing product of claim 19, wherein saidthermoplastic polymer fibers have a mean diameter greater than about 40microns.
 23. The scrubbing product of claim 19, wherein saidthermoplastic polymer fibers comprise polypropylene.
 24. The scrubbingproduct of claim 19, wherein said abrasive layer comprises two or moredifferent thermoplastic polymer fibers.
 25. The scrubbing product ofclaim 24, wherein said different thermoplastic polymer fibers aresubstantially homogeneously distributed within said abrasive layer. 26.The scrubbing product of claim 24, wherein said different thermoplasticpolymer fibers are heterogeneously distributed within said abrasivelayer.
 27. The scrubbing product of claim 1, wherein said abrasivefibers comprise multi-component fibers.
 28. The scrubbing product ofclaim 1, wherein said abrasive fibers are greater than about 1 cm inlength.
 29. The scrubbing product of claim 1, wherein said abrasivelayer has an average thickness greater than about 0.5 mm.
 30. Thescrubbing product of claim 1, wherein said abrasive layer has an averagethickness between about 0.5 and about 10 mm.
 31. The scrubbing productof claim 1, wherein said abrasive layer further comprises particulatematter, said particulate matter increasing the abrasiveness of saidabrasive layer.
 32. The scrubbing product of claim 1, wherein saidabrasive layer has a basis weight greater than about 10 gsm.
 33. Thescrubbing product of claim 1, wherein said abrasive layer has a basisweight greater than about 50 gsm.
 34. The scrubbing product of claim 1,wherein more than about 5% of the superficial area of the abrasive layerincludes pores providing direct optical access to the cellulosic web.35. The scrubbing product of claim 1, wherein about 30% or more of thesuperficial area of the first surface includes pores extending throughthe axial depth of said abrasive layer.
 36. The scrubbing product ofclaim 1, wherein more than about 50% of the superficial area of theabrasive layer includes pores providing direct optical access to thecellulosic web.
 37. The scrubbing product of claim 1, wherein saidcellulosic web has a basis weight greater than about 10 gsm.
 38. Thescrubbing product of claim 1, wherein said cellulosic web comprisesgreater than about 5 dry weight percent high yield pulp fibers.
 39. Thescrubbing product of claim 38, wherein said cellulosic web comprisesfrom about 15 to about 40 dry weight percent high yield pulp fibers. 40.The scrubbing product of claim 1, wherein said absorbent layer comprisestwo or more cellulosic webs adhesively secured together.
 41. Thescrubbing product of claim 1, wherein said cellulosic web has a wetopacity less than about 98%.
 42. The scrubbing product of claim 41,wherein said cellulosic web has a dry opacity, the difference betweenthe dry opacity and the wet opacity is about 10% or greater.
 43. Thescrubbing product of claim 1, wherein said cellulosic web has a dryopacity less than about 96% and wet opacity less than about 90% whereinthe difference between the dry opacity and the wet opacity is about 10%or greater.
 44. The scrubbing product of claim 1, wherein saidcellulosic web has a wet opacity less than about 80%.
 45. The scrubbingproduct of claim 1, wherein said cellulosic web has a cross-directionwet:dry strength ratio greater than about 0.1.
 46. The scrubbing productof claim 1, wherein said cellulosic web has a cross-direction wet:drystrength ratio greater than about 0.4.
 47. The scrubbing product ofclaim 1, wherein said abrasive layer is adhesively bonded to saidabsorbent layer.
 48. The scrubbing product of claim 1, wherein saidabrasive layer is thermally bonded to said absorbent layer.
 49. Thescrubbing product of claim 1, further comprising a hydrophobic barrierlayer on at least a portion of a surface of the absorbent layer.
 50. Thescrubbing product of claim 49, wherein said barrier layer is betweensaid abrasive layer and said absorbent layer.
 51. The scrubbing productof claim 49, further comprising a second outer surface opposite theabrasive outer surface, the second outer surface comprising said barrierlayer.
 52. The scrubbing product of claim 51, wherein said barrier layeris a removable barrier layer.
 53. The scrubbing product of claim 49,wherein said barrier layer is a hydrophobic film.
 54. The scrubbingproduct of claim 1, wherein the scrubbing product contains an additiveassociated with the scrubbing product, the additive comprising a soap, adetergent, a buffering agent, an antimicrobial agent, a skin wellnessagent, a lotion, a medication, a polishing agent, and mixtures thereof.55. The scrubbing product of claim 1, wherein said abrasive layer has abasis weight greater than about 50 gsm.
 56. The scrubbing product ofclaim 1, wherein said abrasive fibers comprise aggregate fibers havingnon-circular cross-sections, said aggregate fibers comprising two ormore individual fibers aligned in a side-by-side arrangement along atleast 5 mm of the length of the aggregate fiber.
 57. The scrubbingproduct of claim 56, comprising a plurality of aggregate fibers withcross-sections having an aspect ratio of about three or greater.
 58. Thescrubbing product of claim 56, wherein said aggregate fibers compriseabout 5% or greater of the mass of said abrasive fibers.
 59. Thescrubbing product of claim 56, wherein said aggregate fibers compriseabout 40% or greater of the mass of said abrasive fibers.
 60. Thescrubbing product of claim 56, wherein said aggregate fibers compriseforked aggregate fibers.
 61. The scrubbing product of claim 56, whereinsaid multifilamentary aggregate fibers comprise twisted multifilamentaryaggregate fibers.
 62. The scrubbing product of claim 1, wherein theabrasive layer comprises a metallocene polymer.
 63. The scrubbingproduct of claim 1, wherein the abrasive layer comprises a polymerhaving a melt flow rate of about 2000 g/10 min or less.
 64. Thescrubbing product of claim 1, wherein the abrasive layer comprises apolymer having a melt flow rate of about 100 g/10 min or less.
 65. Thescrubbing product of claim 1, wherein the abrasive layer has been moldedagainst a three-dimensional surface to impart a repeating pattern ofunit cells having elevated regions, the unit cells having an area ofabout 5 square millimeters or greater.
 66. The scrubbing product ofclaim 1, wherein the paper web has a Surface Depth of about 0.2 mm orgreater.
 67. The scrubbing product of claim 66, wherein the paper webhas a repeating pattern or elevated and depressed regions with acharacteristic unit cell having an area of about 5 square millimeters orgreater.
 68. The scrubbing product of claim 1, wherein the abrasivelayer has an Abrasiveness Index of about 1 or greater.
 69. The scrubbingproduct of claim 1, wherein the abrasive layer has an Abrasiveness Indexof about 5 or greater.
 70. The scrubbing product of claim 1, wherein theabrasive layer has an Air Permeability greater than about 500 CFM. 71.The scrubbing product of claim 1, wherein said scrubbing product is adishwashing wipe.
 72. The scrubbing product of claim 1, wherein saidscrubbing product is a scouring pad.
 73. The scrubbing product of claim1, wherein said scrubbing product is a polishing pad.
 74. The scrubbingproduct of claim 1, wherein said scrubbing product is a sanding pad. 75.The scrubbing product of claim 1, wherein said scrubbing product is apersonal cleansing pad.
 76. The scrubbing product of claim 75, whereinsaid cleansing pad is an exfoliating pad.
 77. A scrubbing productcomprising: an abrasive layer comprising a meltblown web comprisingthermoplastic polymer fibers greater than about 40 microns in meandiameter and greater than about 1 cm in length in a random distribution,said meltblown web having an average thickness greater than about 0.5 mmand an open, porous structure defining open space within the abrasivelayer comprising greater than about 10% of the total volume of theabrasive layer; an absorbent layer comprising a cellulosic web having abasis weight greater than about 10 gsm; and wherein said abrasive layeris secured to said absorbent layer, said abrasive layer forming anabrasive outer surface on said scrubbing pad.
 78. The scrubbing productof claim 77, further having a Strength Synergy of about 1.1 or greater.79. The scrubbing product of claim 77, further having a Strength Synergyof about 1.5 or greater.
 80. The scrubbing product of claim 77, furtherhaving a Stretch Synergy of about 1.1 or greater.
 81. The scrubbingproduct of claim 77, further having a Stretch Synergy of about 1.5 orgreater.
 82. The scrubbing product of claim 77, wherein the cellulosicweb has an Overall Surface Depth of about 0.3 mm or greater on at leastone side.
 83. The scrubbing product of claim 77, wherein saidthermoplastic polymer comprises polypropylene.
 84. The scrubbing productof claim 77, wherein said polymer fibers have a mean diameter betweenabout 40 microns and about 400 microns.
 85. The scrubbing product ofclaim 77, wherein said abrasive layer further comprises particulatematter, said particulate matter increasing the abrasiveness of saidproduct.
 86. The scrubbing product of claim 77, wherein the AirPermeability of said abrasive layer is greater than about 100 CFM. 87.The scrubbing product of claim 77, wherein the abrasive layer has anaverage thickness greater than about 0.7 mm.
 88. The scrubbing productof claim 77, wherein the abrasive layer has an average thickness betweenabout 2 mm and about 10 mm.
 89. The scrubbing product of claim 77,wherein the cellulosic web is reinforced with a continuous polymernetwork.
 90. The scrubbing product of claim 77, wherein the cellulosicweb is reinforced with an impregnated adhesive.
 91. The scrubbingproduct of claim 77, wherein said abrasive layer has a basis weightbetween about 25 gsm and about 100 gsm.
 92. The scrubbing product ofclaim 77, wherein said abrasive layer has a basis weight of about 50 gsmor greater.
 93. The scrubbing product of claim 77, wherein saidcellulosic web has a basis weight between about 20 gsm and about 100gsm.
 94. The scrubbing product of claim 77, wherein said cellulosic webcomprises from about 5 to about 30 dry weight percent high yield pulpfibers.
 95. The scrubbing product of claim 77, wherein said cellulosicweb has a wet opacity less than about 98%.
 96. The scrubbing product ofclaim 77, wherein said cellulosic web has a wet opacity less than about80%.
 97. The scrubbing product of claim 77, wherein said cellulosic webis a throughdried cellulosic web.
 98. The scrubbing product of claim 77,wherein said abrasive layer is thermally bonded to said absorbent layer.99. The scrubbing product of claim 77, wherein said abrasive layer isadhesively secured to said absorbent layer.
 100. The scrubbing productof claim 77, further comprising a hydrophobic barrier layer on at leasta portion of a surface of the absorbent layer.
 101. The scrubbingproduct of claim 100, wherein said barrier layer is between saidabrasive layer and said absorbent layer.
 102. The scrubbing product ofclaim 100, wherein said barrier layer is a hydrophobic film.
 103. Thescrubbing product of claim 77, wherein the scrubbing product contains anadditive associated with the product, the additive comprising a soap, adetergent, a buffering agent, an antimicrobial agent, a skin wellnessagent, a lotion, a medication, a polishing agent, and mixtures thereof.104. The scrubbing product of claim 77, wherein the cellulosic web has across-direction wet:dry strength ratio greater than about 0.3.
 105. Thescrubbing product of claim 77, wherein the cellulosic web has across-direction wet:dry strength ratio greater than about 0.4.
 106. Thescrubbing product of claim 77, wherein the cellulosic web has across-direction wet:dry strength ratio greater than about 0.5.
 107. Thescrubbing product of claim 77, wherein said abrasive layer comprises atleast about 5 weight % aggregate fibers having cross-sections with anaspect ratio of about two or greater, said aggregate fibers comprisingtwo or more abrasive fibers in a side-by-side arrangement along at leastabout 5 mm of the length of said aggregate fiber.
 108. The scrubbingproduct of claim 107, wherein a region of the product 3 centimeterssquare comprises an average of at least one twisted multifilamentaryaggregate fiber making a twist of at least 180 degrees about its axisalong a fiber path length no longer than 3 cm.
 109. The scrubbingproduct of claim 107, wherein a region of the product 3 centimeterssquare comprises an average of at least 10 twisted multifilamentaryaggregate fibers making a twist of at least 180 degrees about theirrespective axes.
 110. The scrubbing product of claim 77, wherein theabrasive layer has an Abrasiveness Index of about 1 or greater.
 111. Ascrubbing product comprising: an abrasive layer comprising meltspunpolymeric abrasive fibers greater than about 40 microns in mean diameterand greater than about 1 cm in length in a random distribution, saidabrasive layer having an open, porous structure defining void spacewithin the abrasive layer comprising greater than about 10% of the totalvolume of the abrasive layer and an average thickness greater than about1 mm; an absorbent layer comprising a cellulosic web having a basisweight greater than about 10 gsm and a geometric mean wet:dry strengthratio greater than about 0.1; wherein said abrasive layer is secured tosaid absorbent layer, said abrasive layer forming an abrasive outersurface on said scrubbing pad; and wherein more than about 30% of thesurface of said abrasive layer defines voids extending across the axialdepth of said abrasive layer and said absorbent layer has a wet opacityof less than about 98%.
 112. The scrubbing product of claim 111, whereinthe cellulosic web is reinforced with a polymer network.
 113. Thescrubbing product of claim 111, wherein the cellulosic web is reinforcedwith impregnated latex.
 114. The scrubbing product of claim 111, whereinthe cellulosic web is reinforced with impregnated hotmelts.
 115. Thescrubbing product of claim 111, wherein said polymeric fibers aretranslucent.
 116. The scrubbing product of claim 111, wherein saidabrasive layer has a basis weight greater than about 50 gsm.
 117. Thescrubbing product of claim 111, wherein said polymeric fibers comprisepolypropylene.
 118. The scrubbing product of claim 111, wherein saidpolymeric fibers have a mean diameter between about 40 microns and about400 microns.
 119. The scrubbing product of claim 111, wherein more thanabout 50% of the superficial area of said abrasive layer includes poresextending through the axial depth of said abrasive layer.
 120. Thescrubbing product of claim 111, wherein said abrasive layer has a basisweight between about 25 gsm and about 100 gsm.
 121. The scrubbingproduct of claim 111, wherein said cellulosic web has a basis weightbetween about 20 gsm and about 100 gsm.
 122. The scrubbing product ofclaim 111, wherein the cellulosic web has a geometric mean wet:drystrength ratio greater than about 0.3.
 123. The scrubbing product ofclaim 111, wherein the cellulosic web has a geometric mean wet:drystrength ratio greater than about 0.4.
 124. The scrubbing product ofclaim 111, wherein said absorbent layer has a wet opacity less thanabout 80%.
 125. The scrubbing product of claim 111, wherein saidabsorbent layer has a wet opacity less than about 60%.
 126. Thescrubbing product of claim 111, wherein said abrasive layer is thermallybonded to said absorbent layer.
 127. The scrubbing product of claim 111,wherein said abrasive layer is adhesively secured to said absorbentlayer.
 128. The scrubbing product of claim 111, wherein the scrubbingproduct contains an additive associated with the product, the additivecomprising a soap, a detergent, a buffering agent, an antimicrobialagent, a skin wellness agent, a lotion, a medication, a polishing agent,and mixtures thereof.
 129. The scrubbing product of claim 111, whereinthe abrasive layer has an Air Permeability greater than about 100 CFM.130. The scrubbing product of claim 111, wherein said abrasive layer hasan average thickness between about 2 mm and about 10 mm.
 131. Thescrubbing product of claim 111, wherein the abrasive layer comprisesaggregate fibers, said aggregate fibers comprising two or more abrasivefibers in a side-by-side arrangement for at least about 5 mm along thelength of the aggregate fiber.
 132. The scrubbing product of claim 131,wherein the aggregate fibers comprise from about 2 to about 50 polymerfilaments.
 133. The scrubbing product of claim 111, wherein the abrasivelayer has an Abrasiveness Index of about 1 or greater.
 134. Thescrubbing product of claim 111, wherein the scrubbing product has a wetopacity less than 98%.
 135. A cleaning tool comprising: a handle; arigid base attached to said handle; and a scrubbing pad attached to saidrigid base, said scrubbing pad comprising an absorbent layer comprisinga cellulosic web and an abrasive layer comprising a nonwoven webcomprising abrasive fibers in a random distribution, said abrasive layerhaving an open, porous structure defining more than about 10% of saidabrasive layer as void space, wherein said abrasive layer and saidabsorbent layer are bonded together.
 136. The cleaning tool of claim135, wherein said abrasive fibers comprise a thermoplastic polymer. 137.The cleaning tool of claim 135, wherein said thermoplastic polymercomprises polypropylene.
 138. The cleaning tool of claim 135, whereinsaid cellulosic web is an uncreped, throughdried cellulosic web. 139.The cleaning tool of claim 135, wherein said abrasive layer and saidabsorbent layer are thermally bonded together.
 140. The cleaning tool ofclaim 135, wherein said abrasive layer and said absorbent layer andadhesively bonded together.
 141. The cleaning tool of claim 135, furthercomprising an additive associated with the scrubbing pad, the additivecomprising a soap, a detergent, a buffering agent, an antimicrobialagent, a skin wellness agent, a lotion, a medication, a polishing agent,and mixtures thereof.
 142. The cleaning tool of claim 135, wherein theabrasive layer has an average thickness greater than about 0.7 mm. 143.The cleaning tool of claim 135, wherein the cellulosic web has ageometric mean wet:dry strength ratio greater than about 0.3.
 144. Thecleaning tool of claim 135, wherein the cellulosic web has a geometricmean wet:dry strength ratio greater than about 0.4.
 145. The cleaningtool of claim 135, wherein the cellulosic web has a geometric meanwet:dry strength ratio greater than about 0.6.
 146. The cleaning tool ofclaim 135, wherein the abrasive layer comprises aggregate fibers, saidaggregate fibers comprising two or more abrasive fibers in aside-by-side arrangement along at least 5 mm of the length of theaggregate fiber.
 147. The scrubbing product of claim 135, wherein theabrasive layer has an Abrasiveness Index of about 1 or greater.
 148. Thescrubbing product of claim 135, wherein the abrasive layer has anAbrasiveness Index of about 5 or greater.
 149. The cleaning tool ofclaim 135, wherein said cleaning tool is a mop.
 150. The cleaning toolof claim 135, wherein said cleaning tool is a toilet cleaning tool. 151.The cleaning tool of claim 135, wherein said cleaning tool is a wallcleaning tool.
 152. The cleaning tool of claim 135, wherein saidcleaning tool is a window cleaning tool.
 153. The cleaning tool of claim135, wherein said cleaning tool is a sanding tool.
 154. The cleaningtool of claim 135, wherein said cleaning tool is a polishing tool. 155.The cleaning tool of claim 135, further comprising a squeegee attachedto said cleaning tool.
 156. The cleaning tool of claim 135, wherein saidscrubbing pad is removeably attached to said rigid base.
 157. Thecleaning tool of claim 135, wherein said scrubbing pad is permanentlyattached to said rigid base.
 158. A method of forming a scrubbingproduct comprising: forming an abrasive layer comprising polymericfibers in a non-uniform distribution such that the thickness of theabrasive layer varies across the width of the abrasive layer, saidabrasive layer having an open, porous structure and an Air Permeabilitygreater than about 100 CFM; forming an absorbent layer comprising afibrous cellulosic web; and securing said abrasive layer to saidabsorbent layer such that said abrasive layer forms an outer surface ofsaid scrubbing product.
 159. A method according to claim 158, whereinsaid absorbent layer comprises an uncreped, throughdried paper web. 160.A method according to claim 158, wherein the uncreped, throughdried webis a stratified web.
 161. A method according to claim 158, wherein saidabrasive layer comprises thermoplastic polymeric fibers.
 162. A methodaccording to claim 158, wherein said abrasive layer comprises meltblownpolymeric fibers.
 163. A method according to claim 162, wherein themeltblown die comprises a multi-section die.
 164. A method according toclaim 162, wherein the meltblown polymeric fibers are deposited from ameltblown die onto a surface of the absorbent layer.
 165. A methodaccording to claim 158, wherein the abrasive layer has an averagethickness greater than about 0.5 mm.
 166. A method according to claim158, further comprising forming a precursor web, said precursor webcomprising attenuated thermoplastic fibers, and heating said precursorweb to a temperature less than the melting point of the thermoplasticfibers such that a portion of the attenuated fibers shrink to formnodulated fiber remnants, wherein the abrasive layer comprises thenodulated fiber remnants.
 167. A method according to claim 158, whereinthe meltblown die comprises a multi-section die.
 168. The method ofclaim 167, further comprising extruding said aggregate fibers from ameltblown die comprising a die head to a carrier fabric beneath said diehead, the carrier fabric being between about ten inches and about fiveinches beneath die head.
 169. The method of claim 168, wherein the diehead is about seven inches above the carrier fabric.
 170. The method ofclaim 168, wherein the meltblown die further comprises a pressurized airsource for delivery of an air flow at between about 3 and about 20 psig.171. The method of claim 168, the meltblown die further comprising apressurized air source for delivery of an air flow at between about 12and about 20 psig.
 172. A method according to claim 158, wherein saidabrasive layer comprises polymeric multifiliamentary aggregate fibers.173. A method according to claim 158, wherein the abrasive layer isformed on a highly textured forming belt.
 174. A method according toclaim 158, wherein the abrasive layer and the absorbent layer areadhesively secured together.
 175. A method according to claim 174,wherein the abrasive layer and the absorbent layer are adhesivelysecured together with a hot melt adhesive.
 176. A method according toclaim 175, wherein the hot melt adhesive is applied to either a surfaceof the abrasive layer or a surface of the absorbent layer in a pattern.177. A method according to claim 158, wherein the absorbent layer andthe abrasive layer are secured together by a process selected from thegroup consisting of ultrasonic bonding, mechanical bonding, andapplication of heat causing at least partial fusion of the meltblownlayer with the absorbent layer.
 178. A method according to claim 158,wherein the absorbent layer and the abrasive layer are secured togetherby the application of heat and pressure to the absorbent layer and theabrasive layer as the layers are held adjacent to one another.
 179. Amethod according the claim 158, further comprising attaching a barrierlayer to the scrubbing product.
 180. A method according to claim 179,wherein the barrier layer is attached to the scrubbing product betweenthe abrasive layer and the absorbent layer.
 181. A method according toclaim 179, wherein the barrier layer is attached to a surface of thescrubbing product opposite the abrasive layer.
 182. A method accordingto claim 158, further comprising incorporating an additive to thescrubbing product.
 183. A dishcloth comprising: an abrasive layercomprising abrasive polymeric fibers in a non-uniform distribution suchthat the thickness of the abrasive layer varies across the width of theabrasive layer, said abrasive layer having an open, porous structurewith an Air Permeability of about 100 CFM or greater; an absorbent layercomprising a fibrous cellulosic web; and wherein said abrasive layer issecured to said absorbent layer, said abrasive layer forming an outersurface of said dishcloth.
 184. The dishcloth of claim 183, wherein saidcellulosic web comprises an uncreped, throughdried cellulosic web. 185.The dishcloth of claim 183, wherein said cellulosic web comprises eitheran airlaid web or a coform web.
 186. The dishcloth of claim 183, furtherhaving a Strength Synergy of about 1.05 or greater.
 187. The dishclothof claim 183, further having a Stretch Synergy of about 1.1 or greater.188. The dishcloth of claim 183, further having an Air Permeability ofabout 30 cubic feet per minute or greater.
 189. The dishcloth of claim183, wherein the product is substantially latex free.
 190. The dishclothof claim 183 having a machine direction Gurley stiffness of about 2500mg or less.
 191. The dishcloth of claim 183 having a machine directionGurley stiffness of about 500 mg or less.
 192. The dishcloth of claim183, wherein said abrasive fibers comprise thermoplastic polymer fibershaving a melting point of about 120° C. or greater.
 193. The dishclothof claim 192, wherein said thermoplastic polymer is selected from thegroup consisting of polypropylene, polyethylene, polyesters,high-density polypropylene, polystyrene, polyamides, polyvinylidenes,polyvinyl chloride, polyurethane, polyurea, and copolymers thereof. 194.The dishcloth of claim 193, wherein said thermoplastic polymer fibershave a mean diameter greater than about 40 microns.
 195. The dishclothof claim 183, wherein said abrasive fibers comprise polypropylene. 196.The dishcloth of claim 183, wherein said abrasive layer comprises two ormore different thermoplastic polymer fibers.
 197. The dishcloth of claim183, wherein said abrasive fibers comprise multi-component fibers. 198.The dishcloth of claim 183, wherein said abrasive fibers are greaterthan about 1 cm in length.
 199. The dishcloth of claim 183, wherein saidabrasive layer has a basis weight greater than about 10 gsm.
 200. Thedishcloth of claim 183, wherein more than about 10% of the superficialarea of the abrasive layer is occupied by pores providing direct opticalaccess to the cellulosic web.
 201. The dishcloth of claim 183, whereinsaid cellulosic web has a basis weight greater than about 10 gsm. 202.The dishcloth of claim 183, wherein said cellulosic web comprisesgreater than about 5 dry weight percent high yield pulp fibers.
 203. Thedishcloth of claim 183, wherein said absorbent layer comprises two ormore cellulosic webs adhesively secured together.
 204. The dishcloth ofclaim 183, wherein said abrasive layer is adhesively bonded to saidabsorbent layer.
 205. The dishcloth of claim 183, wherein the dishclothcontains an additive associated with the dishcloth, the additivecomprising a soap, a detergent, a buffering agent, an antimicrobialagent, a skin wellness agent, a lotion, a medication, a polishing agent,and mixtures thereof.
 206. The dishcloth of claim 183, wherein saidabrasive fibers comprise multifilamentary aggregate fibers havingnon-circular cross-sections.
 207. The dishcloth of claim 206, comprisinga plurality of multifilamentary aggregate fibers with cross-sectionshaving an aspect ratio of about three or greater.
 208. The dishcloth ofclaim 206, wherein said multifilamentary aggregate fibers comprise about5% or greater of the mass of said abrasive fibers.
 209. The dishcloth ofclaim 183, wherein the cellulosic web has a Surface Depth of about 0.2mm or greater.
 210. The dishcloth of claim 183, wherein the abrasivelayer has an Abrasiveness Index of about 1 or greater.
 211. Thedishcloth of claim 183, wherein the abrasive layer has an AbrasivenessIndex of about 5 or greater.
 212. The dishcloth of claim 183, whereinthe cellulosic web has a cross-direction wet:dry strength ratio greaterthan about 0.10.
 213. The dishcloth of claim 183, wherein the cellulosicweb has a cross-direction wet:dry strength ratio greater than about0.40.
 214. The dishcloth of claim 183, wherein the cellulosic web has across-direction wet:dry strength ratio greater than about 0.60.
 215. Thedishcloth of claim 183, wherein the cellulosic web has a wet tensilestrength greater than about 200 g/3 g H₂O.
 216. The dishcloth of claim183, wherein the cellulosic web as a wet tensile strength greater thanabout 500 g/3 g H₂O.
 217. The dishcloth of claim 183, wherein thecellulosic web as a wet tensile strength greater than about 1,500 g/3 gH₂O.
 218. The dishcloth of claim 183, wherein the cellulosic web as awet tensile strength between about 500 g/3 g H₂O and about 2,500 g/3 gH₂O.
 219. The dishcloth of claim 183, said dishcloth having an AirPermeability greater than about 50 CFM.
 220. The dishcloth of claim 183,said dishcloth having a wet opacity less than about 90%.